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 Desiroy superseded pages, PREPARED UNDER AUTHORITY OF THE NATICNAL AERONAUTICS AND SPACE ADMINISTRATION " ] APRIL 1969 CHANGE NO. 14 9 OCTOBER 1972 R-3896-11 LIST OF EFFECTIVE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 Page No oR 80 terre A tino He, Vio thea ddi..... iv tira iA GSB. a thru viesss ee shh thro sl(..., CS | eee eoue ME VEP Lecce eee eli theu sddav sliift.c. . x fhra #\.wu. eee Meee eevee neces wheweaae sotasere Ps. ee MTEL ce cecavaee St ea eveutige xv HE cece Veh cccesesnaans Yi) piace tae deere caeav +3... thaeeee Ihveees l-3 thra lef... LaFicsevnee L-# thin 1-9,... tel... PaTd i rcecsteeeae J-10 thr lta... | i eer ae i) eee eee Val, voeeeae yao 1-18.,.. | ed herrea 1-20 thru 1-21.. (oUa.... PRD cea sea eas 1=24 thru le24p. Us eee Sere hd Deere ar err 1-8 thru 1-29,. | od | a veaee 1-31 thra 1-32.. UnSB. cer vescenee =¥. itera 1=35.. thd aeage verbo nnae Bec aae teeiee 237 ecrecveccnen TstR. eee eee ‘ DARD. cence enaee 1-40 thro lL“"“),. LAND. cere e enon 1.24 thru 120/142. 143 thru 1-45... 1-46 thru I-NGA/IMAGR. 1"? thru 1-48... 1-A8A thru '-4BN LehaC/I—ABD.. oe lic cccereriee 1-50... 1-51 thru 1#52,, 1-53.. Leo Oe Re 1-55 thru 1+"6,. 1-97.... pene ener phan eee ene venga = Aero wronowses won wilh lisve Net et Sep Ap sy ort Apr Vet Apr May Sess sg tatat sists oto lois tt bt seoe Ordgpenal ceee O May 71 oar OD uy flet Apr ~ ie 7) t Oct 72 2A Npre 72 coos Original 2.8 Apr 70 cent Orb yioal eee wR 2 eases cease fb rowers it) eoae G sara OP seael seae D Apr bee Apr May Feb Many Oct May fet 70 70 re 7. mi 7 ho 7) on 2 € vooe Original ieee reee D eee atin sone F svoeall Pere Ct) Oet Vet May Oct Ort Apr Feb 70 202.28 Apr 70 aeee Original wore 2 Dee 70 » OAct 72 a+e-10 Poh 70 vee e2B AUR 71 wees Dedginal veee2h Ape 70 o tree Dec 70 » Original eee lO wnNn 4 Fel sep Feb Oct Sep Sep Sep Dec Nec Sep Apr 7 ri 7 69 70 wea. Original 22-28 Apr 79 ~... Original seer F Sep 70 seve Qriginal seca Sop 70 aeeel Feb 70 490 Page No i- 38 thro 1-59... VHD. cc cae enn vaee 1-604 thr 1-a0b. st) rr We thea l-5... hy een ea l-O4...00. re [Se O sir s aceretes ese P=PZDA/L=7OB. eos 1+71 thru LPIA HAT AN ee 1-73..... ooernace V=7% thru 1-76. 1-776. . eee Are 1-74 thro L+7a&4.. VHT ccc eee LHTAC cece rena ene L=7AD, . wc eae eee 1=75H/1-78F. i.e L-79... Pan eaeeewe UMD. cece on be4L thru IA2,.. Ch Seer IA4 thra PBAA/IASMT cee IBS... VAR cece eens VAP cecerencenns 1-88, jee ers 1-49 thru 1-90,.. 1-91 thru 1-A/1-92H ee, I~} thera 1=94... 1-9T/ IH ce caeee 197/109. eee [=i vices ena kare IHLOO wees T-10l,.. 0... oe 1+102 thrn 1-104. 1-104 thre 1-105. Vek here caine ea 1+107 ¢hru 1l-1d2, 1-109 thru b-ll1. 2) Le V=113 thro l 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 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 = a ®, (84 wn So wv tems Ox - ' voslee |=o¢l #8] 2 pea) os oof] AE = aoki rs Be el se &p aol al Bae 3 ih cu - able a San] Se | BE a>] a) 3 os 18ES nom Owns! SS oo] oz 3 3 2) 2 ]ae | £ [280 bea] os pl pe | Se) at, 2 | se = _ Teds Wee te o 3 el Sel aye o & Sy a5 “8 Sg | 38 a oes feel ee a Peel BO | gael Bal sg Pas| wn . Si/aca q_|/At |OOk|BPShi want Pe | SH} ok | aa A, | 8 Fo] Gn I J K 1,5,12 1,6.12 £.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 ° 2 Ss ool oo ae eles H > Shee a! € Owl ay ato Sle akhl|e ew oO + 1 SO Onl ww fw] w e\Soggey)s SE | 22 e) 82 sl B ae | OA 2 SS a] P Change No. 11 - 6 May 1971 Subsequent to Start of __ Automatic Sequence Hypergol Burst to Vehicle Lift-Off > 1-9 OI-T 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. +2] rar TI-9686-u I uo}pag ti-t 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 J Woypoag _ ' = oe 2L6T 49Q0799 g - PI "ON aBuLYyD 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 I Uot}o08 T1-968¢-4 Gt-l xe Sy Pr ppp 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 ] WoT BI-t 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 LI-k part - aoe Seem | ee S eee T1-9686-H J “Oyo ag BI-T TABI ABW g - EE “ON odueyy) 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. on = I UOp}VAS TT-988€-H 696T 4999390 6 - ¢ “ON adUEYD 6I-T 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 I uoyj2ag 0z@-1 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. } UdpPAY Ty¥-968e-t 246} 1940100 @ - PT "ON @3uRYD Té-T 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 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 i] 919 ] uopPaS TI-968E-U ZLET 19Q0]0O G@ ~ PI “ON aduryD Le-T ee Paragraph Activities Requirements Limits Speeial Constraints and Remarks a er yee 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 11-9$68¢-H ] Worn.s 8e-T OLET Azensgag OT - 9 “ON aduLYyD a ee Paragraph 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. J WOIDAS5 TT-9608¢-4 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- ¢ OLGT 42en2q94 OT - 9 ‘ON aBUEYD (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, = IT-9686-U J votjoas oft re) IL6y yondny eg - ZE "ON OFuey Paragraph 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- TL uotpas TI-9688-4 1e-1 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 1 Woya3Z 4 Paragraph ve t> nm 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. I woyIag Ti-9686-H OL6I Uady gz - 2 “ON edueyg eect Special Constraints 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. 902 TT-9688-u ] uorpas vE-T OL6T Joquiadaq Zz - § ‘ON aBuvyy ih SS SS Sy Paragraph an a PE oa ee ee aE 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. J uoyyv05 TI-9686-H OLGL Fequiasag Zz - g “ON DAUBYD St-T Paragreph 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 Perform prior to installation on h on engine, | 916 = 916 2 Perform prior to igniter installation. TE -9688-u [ woras & Paragraph Activities 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. J WOTJOS TI-968¢-u 7 Special Constriints Paragraph Activities Requirc ments Limits and Remarks 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 TT-968€-U OLG1 Auenaqog O1 - 9 ‘ON aHuLY) -{ Le J Woljoas ge ‘ON adueyy) OLGE 1aqtuaydus 6 - g Paragraph 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. I toraes L1-968¢-4 OLGI Arensqag OL - 9 "ON aBuReYD 6E-T Paragraph 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- $2 ance of this activity. Thrust chamber exit and throat closures and LOX overboard drain line closure must be removed during this test. Leak-cest compound must not be used on overboard drain line exits or braided flex line bellows, Perform after exhaust system leak test and sequence verifi- cation test. Thrust chamber exit and throat closures; and LOX overboard drain line closure must be re- moved during this test. Leak-test compound must not be used on overboard drain line exits or braided flex line bellows. IT-968€-U ] worpaasg OF-1 ‘ON OFuvyy 696E J8G0W0 6 ~ S ——————$———$——— LS Paragraph 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. 901 I Worpoas TT-9686-u 6967 4840990 6 - § “ON eauEYD TP-E ~~ —-—O rr Paragraph 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. TI-968£-Y } mores cbrT OLGT Jaquaqdag 3 - g “ON BAUEYD Special Constraints 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} 915 1 “OT}PaS 11-968¢-U OLGT Je0w7A4ag g - g ‘ON a#URYD Veb-t yc Paragraph 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. 913 913 IT- 9686-4 J ¥aq}2aS uep-i OLBL tequujdos g - y ‘ON odtEYs) HEAT EXCHANGER HELIUM SYSTEM LEAK TEST AT MTF_ 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. 913 913 1 u0}}30$ TT -€8eé -U OL6} Aaquajdug g = B ‘ON OduEYy) Gzep-l/Ozb-3 Special Constraints 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 Tt-9686-U J WO}}IaS OLGT 4aquajdag g§ - g ‘ON OFuEND Ad | Poragraph Activities 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) i1-968€-U [ Uolag PPT OLEL tsqualdeg § - g "ON oduLYs) Special Constraints 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. a 900 J Wong IT -968E-2 OLGI taquiajtlag G - g ‘ON adUEYD Sel 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 1T-9686 -H [ Wor ag or-T OLGE Jaquavad g - B ON JduLYy:) Parzgraph 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. ] "WupJI0g [IT -968¢~-u OLGL FoQwasagq Z - g ‘oN wéuLyy Ob T/VOP-T RR ey er Requirements imits Special Constraints and Remarks _— Tye a ere er 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, IT -968E-U ] Woraag OLGI t8qQWIaZ0q g~ - G ‘UN eduRYD Le-f 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. TT -9688 -u 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. J UGT}Oag Br-T OLGE 49QuUId00q Z - 6 “ON aduEYy 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 [ Uo}}Ja9S$ TT -96RE -H OLGI 4aqtuaydas g - g ‘ON VAULYD Veer 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. i 91' : 1 TT-9686-8 1 uO},29g deb-t OLGT 1aqluuydeg 6° 2 ‘ON yuryy 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. ] udy}oaS TE-9688-2 ZL61 Tidy — + 1 ‘ON aduryyy CHE -1/O8br 1 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 No external leakage is allowable. Specr ' Constraints wand Remarcs Perform prior to hydraulic control system le. k test and thrust climber leak test. CAUTION The hvepergol cartridge instuiled swiicn must not be actuated when perform- ing steps a and b. Perform external leak test after measurement of dia- phragm leikage nd recon- nection und torquing of drain tube to ATMOS REF port. Thrust chamber throat plug, closure, and or ext closure must be removed during performance of this activity. Perform prior to thrust cham- ber leak test and fuel feed system leak test. Apply pressure through drain quick- disconect. The hyperzol manifold outlet line must be blucked during this test. If wmiter fuet valve releves at a pressure lower than 200 :10 psig. decrcase pressure until valve reseats. then increase level to value just below that required © r igmiter fuel valve to reheve. Perforni test at this pressure, Perform external leak test ufter completion of wll flow measurements ind after in- Stalltion and torquing of ‘11 flow mé.surement port fittings. $1-968€-4 J woRQIaS BE-t EP Paragraph A stivities 1.3, 21 (cont) 1 3.22 IGNITION MONITOR VALVE INTERFLUW TEST 3.23 IGNITIO™ MONITOR VALVE SHUTTLE PRESSURE TEST Requirements c. Measure and record igniter fuel valve reiieving pressure using miseous nitrogen pres- sure. [Repeat tes. 3 times, } Apply 1,550 +50 psig hydraulic pressure and mechanically simu- late hypergol cartridge instalied. Apply 28 +2 psig giseous nitrogen pressure to ignition monitor valve CONTROL port for 5 ininutes with gis generator ball valve and muio oxidizer valves in open position. Measure and recom miseous nitrogen pressure (applied to CONTROL port) ut which renition monitor valve actuates during 3 cycles with 1,550 +50 psig hy- craulic control system pressure applied. Limits 279 psig maximum Fael valves must remain in the clesed position. 20 +4 psig with sense line to thrust chamber blinked off or 21 -4 pare with sense line to thrust chamber not blanked ott, Each shettte pressure must be within +2 psig of the other shuttle pressures, Speen Constraints and Remarks The enuine fuel feed system must be vented to preciude pressure buildup duriay this test, Perform this test after hy- draulic control system leak test, ignition monitor valve diaphragm leak test, ignition monitor v.lve shuttle pressure test, hypersol installed switch test, und flight instrumentation system test. The engine propellant feed svs- tems must be at ambient pres- sure during this test. CAUTION Suppty pressure to immyi- ftlon monittcr vaive CON- TROL port must not ex- ceed 100 psiyz since damape to rmition munti- tor valve or hypergol manifold ‘il! result. TI-96RE-H e Extreme care must be used when installing the hyperyol test tool, to pre- vent damage to the hyper- 201 cartridie follower. e Threads of the test tool vap mast be clean and free of nicks, to prevent walling of threads of the cap and inlet port. Perform this test after hy- draulie control system leak test, ignition monitor valve diaphragm leak test. hypergel installed switch test, and fheht instrumentation system test. The engine propellant feed sys- tems must be at ambient pren- sure during this test. LMOTP OS og-t OLAT (lady gz - L (ON oduLy:y rm rr rr re Parazraph Activities 1.3.23 {cont} 1.3. 24 VALVE TIMING TEST FOR UL:INSTALLED ENGINES a. Requirements Cycle gus generator bull valve, oxidizer valves, ane fuel valves to the open and closed positions a minimum of 4 times with hydraulic control system pressure ut 1,550 +20 psig ws follows: {i} During eich opening cycle, first open gus generator ball vilve and oxidizer valves; then shuttle the ignition mon- itur valve ta open fuel vulves, (2) For 3 closing cycles, apply a signal to engine contre! valve stop solenoid without a sigral applied to redundiunt shutdown valve. (3) For one closing cycle, apply a signal to redundant shut- down valve without a signal applied t *scing cantroi valve stop solervid. Record the following actual vilve and sequence times for those valve cycles that apply a signel to engine control valve stop solenoid: Specuil Constraints and Remarks Ignition niomtor valve oper- tion is imticated by opening of the fuel valves. Perform this test after hy- draulic control system leak teat, ignition monitor valve interflow test, ignition mon- itor valve diaphrigm leak test, ignition monitor valve shuttle pressure test, and flight instrumentation system test. Checkout valve must be in vround return position. CAUTION The supply pressure to the ignition monitor valve CONTROL port must not evceed 100 psig since damage to the ignition monitor valve and hypergel manifold will result. NOTE FPotentiometer times are for reference only. ] WOT T1-968¢-U IS-t Spe ciul Constraints Paragraph Activities Requirements Limits und Remarks 1,3. 24 {1) Time from power application {cont} to engine control valve start (2) (3) solenoid to valve closed switch dropout indication: ia) No. 1 oxidizer valve {o) No. 2 oxidizer valve {c) Gas generator ball valve Vaive opening times from closed switch dropout indi- cation to cpen switch pickup indication: (a) No. I oxidizer valve (b} No. 2 oxidizer valve ic) Gas generator bali valve (d} No. I fuel valve (e} No. 2 fuel valve ff) Time frorn either fuel valve closed switch dropout to other fuel valve closed switch dropout Time from power applica- tion to engine control valve stop solencid to valve open switch dropout indication: (a) Gas generator ball valve (b) No. 1 oxidizer valve (c) No. 2 oxidizer valve {d} No. 1 fuel valve (e) No. 2 fuel valve 40 +25 40 +25 615 2125 615 +125 690 +150 690 +150 Potentiometer Switch (msec) (ms¢c} 155 +50 155 =50 185 +25 350 +60 359 +69 215 +75 545 2100 545 +109 0 +100 TI-9686-H ] UoRwas : Special Constraints & Paragraph Activities Requirements Limits and Remarks 1.3.24 {45 Valve closing tures from (cont) open Switch dropout indica- tion to closed switch pick- Potentiometer Switch up indication: (msec) (msec) (a) No. 1 oxidizer valve 600 +150 335 +60 (b) No. 2 oxidizer valve 600 +150 335 260 {c) Gas generator ball valve -- 140 +30 (d} No. 1 fuel valve 800 +150 655275 (e) No. 2 fuel valve 800 +150 635475 c. Record time from redundant shut- 0.200 sec maximum down solenoid signal to gas gener- ator bali valve open switch dropout for valve cycle that applied a signal to redundant shutdown valve without a signal applied to engine control valve stop solenoid. d. Measure and record hydraulic flow rate at 1,550 +20 psig supply pres- sure and 45 +20 psig return pres- sure as follows: (1) Valves open 11.6 +1.1 gpm (2) Valves closed 11.6 +1.1 gpm e. Measure and record current drains as follows: (1) Engine control valve start 0. 60 amperes solenoid maximum (2) Engine control valve stop 0.60 amperes solenoid maximum (3) Redundant shutdown 2,0 amperes valve solenoid maximum 1.3.25 VALVE TIMING TEST a. Cycle gas generator ball valve, Perform this test after the hy- FOR INSTALLED ENGINES oxidizer valves, and fuel valves draulie control system leak test, to the open and closed positions ignition monitor valve interflow ini : ; test, ignition monitor valve dia- a minimum of 4 times with hy- phragm leak test, ignition monitor drauiic control system pressure valve shuttle pressure test, and at 1,550 250 psig as follows: flight instrumentation system test. I loyqaag IT- 969e-4 OL6L taquiaydag g - g “ON adUBYD €S-t Special Constrairts Paragraph Activities Requirement} Limits and Remarks 1.3.25 {i} During each opening cycle, The engine propellant feed (cont) first open gas generator systems must be at ambient ball valve and oxidizer valves; then shuttle the ignition mon- itor valve to open fuel valves, (2; (Deleted) (3) For one closing cycle, apply a signal to redundar.t shutdown valve without a signal applied to engine control valve stop solenoid, {4} For 3 closing cycles, apply signals to both engine control valve stop solenoid and redun- dant shutdown valve. Record the following actual valve and sequence times for those valve cycles that apply a signal to both engine control valve stop solenoid and redundant shutdown valve: {1) Time from power application to engine control valve start solenoid to valve closed switch dropout indication: {a} No. 1 oxidizer valve (b) No. 2 oxidizer valve {ce} Gas generator ball valve {2) Valve opening times from closed switch dropout indica- tion to open switch pickup indication: (a) No. 1 oxidizer valve (b} No. 2 oxidizer valve (c) Gas generator bali valve Potentiometer Switch (msec) 40 =25 40425 525 +100 925 +100 (msec) 155 =50 155 +50 145 =25 360 =70 300 +70 170 =50 pressure during this test. Checkout valve must be in ground return position. CAUTION The supply pressure to the ignition monitor valve CONTROL port must not exceed 169 psig Since damage to the ignition monitor ais valve and hypergol manifold will result. NOTE Potentiometer times are for reference only. 1T-968¢-U [ top ag PS -T Special Constraints Paragraph Activities Requirements Limits und Remarks 1.3.25 Potentliometer Switch ut “oN aduey’) T-} Dar qgruph - V.35A (cont) ee Activitirs, (Deleted) (3) 14) d. Leak-test the following flanges: (1) 3} Requirements Turbine manifold outlet to heat exchanger inlet Heat exchanger outlet to hot-cas manifold Turbine manifold temperature transducer to turbine manifold instru- mentation tap TG4a (on engines not incorporati: MDI76 change} Cover plate to turbine manifold instrumentation tap TG4a (on engines incorporating S1D176 change} rat Turbine outlet pressure transducer hase te hoat exchmiger mstrumentation tap TG&c Lintits Fuzz teakare {as defined in section H) 1s allowable. Fuzz leakage (as defined in Section II) is Mlowatcle. Fuzz leakage (as dafined in section Tf) 18 allowable. No leakage is allowable. Fuzz isakage {as defined in section II} is allowable. Special Constraints and Remarks TE-9686 -2t [ UOTjaaS OLG[ Laquiajdag g - g ‘oN aduLYyD 1.3.39 Activities TURBOPUMP BEARING COOLANT SYSTEM LEAK AND FUNCTION TEST THRUST CHAMBER PNEUMATIC LEAK TEST FOR UN- INSTALLED ENGINES a. Requirc ments Supply turbopump LOX seal purge to engine. Leak-test fittings and joints «own- stream of bearing ceclant contre) vaive at 10 +! psig gaseous nitrogen supply pressure. Leak-test at 30 (-0, -3) psig gaseous nitrogen or refrigerant, Type 12, the following components: (1) (Deleted) {2) Measure and record leak- age at the tollowing quick- disconnects {a) No. Land No. 2 threst chamber fuel inlet man fold drains (5) Ignition monitor valve drain (c) Hypergol manifold drair Limits Purge must meet Te- quirements of section ii. No external leak- age is allowable. No external leakaze 1s allowable. 3 scim maximum Special Constraints and Remarks This test must be performed after the LOX pump seal purge leak and function test and fuel feed system leak test. CAUTION Pressure in the drain system must not be allowed tu exceed 15 psig since So damage to drain line yellows can result. The turbine exhaust system must be ventcd during performance of this activity. If purge wrap-around line is not installed, decrease purge supply pressure by 5 psig. oor oe Leak-test compound must not be used on overboard drain line exit or braided flex line bellows. The engine valves vent system must be isolated from the over- board drain system during this test. Perform this test prior ta LOX dome and gas generator LOX in- jector purge leak and function test and after the hydraulic con- trol system leak test, engine valve timing test, ignition mon- 94 itor vaive diaphragm leak test, ignition monitor valve interflow test, nypergol manifold and 1g- niter fuel valve leak and func- tion test, ignition monitor valve shuttle Lressure test, thrust OK pressure switch leak and function test, and heat exchanger LOX system leak test. CAUTION The thrust chamber must be pressurized from the LOX side anddepressurized from the fuel or combustion zone side. I Uopoas TT~ 968¢ 4 OLET T9quMia}das G - G ‘ON AAuRYD £9 -J See rr Spe cial Constraints Paragraph Activities Require nents Limits wad Remarks 1,3. 38 (a) No. land Ne. 2 fuel (econt} valve quick- disconnects (3) Slanges, fittings, joints, and No external leakaze Leak-test compound musi nor be thrust chamber tubes 15 allowable used on braided flex iine bellows. + we os &. Measure and record reverse teak- SC scim maximum Thrust Chamber Throat Plug G3136 and hypergol system test ccol 9021279, age cf prefili check valve at 30 g or equivalent, from Hypergol System (+0, -3} psig gaseous nitrogen or refrigerant, Type 12. CAUTION c. Measure and record reverse- 10 scim maximum flow leakage of LOX dome purge Use extreme care when check valve at 30 ,-0, -3) psiz installing hypergol sys- gaseous nitrozen or refrigerant, tem test tocl, tc prevent Type 12. damage to hypergol car- tridge follower. e Make sure that threads of test tool cap are cleaned and free of nicks, to prevent gail- my threads of cap and iniet port. The heat exchanger LOX system must be blocked during this test. Thrust chamber protective cover and thrust chamber exit, oz:dizer overboard drain iine, and thrust chamber throat closures must be removed duz ig this test. CAUTION During removal and instal- lation of No. 1 and No. 2 fuel inlet manifold quick- disconnect caps. the quick- disconnect body must not be allowed to turn since damage to the quick- disconnect body can result. Tool Kit G3135 must be used for this test. a 03 1J- 9688-1 [ weTyag OLGT 4aquiaydag g - g ‘ON OdULYD aph Activities THRUST CHAMBER a. Requirements Leak-rest at 30 (+0, -3) psig Limits Special Constraints and Remarks Perform this test prior to prefill PNEUMATIC LEAK gaseous nitrogen or refrigerant,: system leak test and LOX dome ol TEST FOR INSTALLED Type 12, the following components: and gas generator LOX injector I ENGINES AT MAF purge leak and function test and (1) (Deleted) after hydraule control system i leak test, engine valve timing 915 {2} Measure and record leak- age at the following quick- disconnects: {a) No. land No. 2 thrust chamber fuel inlet manifold drains (o) Ignition monitor valve drain (c) Hypergol manifold drain (d} No. land No. 2 fuel valve quick- disconnects (3} Flanges, fittings. joints, and thrust chamber externa! tube surfaces 3 scim maximum No external leakaze 1s allowanle, test, ignition monitor valve dia- phragm leak test. ignition mon- itor valve interflow test, hyper- gol manifold and igniter fuel valve leak and function test, ig- nition monitor valve shuttle pres- sure test, thrust OK pressure switch leak and function test, and heat exchanger LOX system leak test. CAUTION The thrust chamber must be pressur:zed from the LOX side and depressur- ized from the fuel or com~- bustion zone side. Leak-test compound must net be used on braided flex line bellows. ] uotpag 11-9688-4 Thrust Chamber Throat Plug G3136 and hypergol system test tool 9021279, fl, or equivalent, from Hypergol System r) Tool Kit G3135 must be used for this test. CAUTION b. Measure and record reverse leak- 50 Scim maximum age of prefill check valve at 30 (-0, -3) psig gaseous nitrogen. c. Measure and record reverse-flow 10 scim maximuni leakage of LOX dome purge check vaive at 30 (-0. -3) psig gaseous nitrogen. The hypergol system tool must be tested for proper operation prior to mount- ing on the hypergol assem- bly. @ Extreme care must be used when installing the hypergol system test tool, to prevent damage to the hypergol car- tridge follower. OLG] 1aywajsdag g - g “ON aduRYD G9~T Special Const» uints Paragraph Activities Requirements Limits and Pemarks 1.3.40 (cont) @ Threads of the test tool cap must be clean and free of nicks, ic prevent galling threads of the cap and inlet port. The heat exchanger LOX system must be blocked during this test. Thrust chamber protective cover and thrust chamber exit, oxi- dizer overboard drain line, and thrust chamber threat closures must be removed during this test. CAUTION During removal and in- stalation of No. 1 and No, 2 fuel inlet mani- fold quick- disconnect caps, the quick- disconnect body must not be allowed to turn since damage to the quick- disconnect body can result. 1.3.40A THRUST CHAMBER a. Leak-test at 30 (+0, -3) psig Perform this test prior to prefill PNEUMATIC LEAK gaseous nitrogen, the follow- system leak test and LOX dome TEST FOR INSTALLED ing components: gas generator LOX injector purge ENGINES AT KSC leak and function test and after {1} {Deleted} hydraulic control system leak test, engine valve timing test, igniticn mcnitor vaive diaphragm leak test, ignition monitor valve (2) Measure and record leak- 3 scim maximum interflow test, hypergol manifold age at the following quick- and igmier fuel valve leak and disconnects: function test, ignition monitor valve shuttle pressure test, thrust 913 TT-9688-Y ] woPaas 99-7 OLGT Jaquigvag % - @ ‘ON oduEYyD Special Constraints Paragraph Activities Requirements Limits and Remarks 1.3. 40A (a) No. l and No. 2 thrust OK pressure switch leak and {cont) chamber fuei inlet mani- function test, and heat exchanger fold drains LOX system leak test. (o) Ignition monitor valve CAUTION drain The thrust chamber must (c) Hypergol mamfotd drain be pressurized from the LOX side and depressur- (d) No. i and No. 2 fuel ized from the fuel or com- valve quick-disconnects bustion zone side. {3) Flanges, fittings, joints, and No external leakage Leak-test compound must not be thrust chamber externai tube is allowable. used on braided flex Line bellows. surfaces Thrust Chamber Throat Plug G3136 and hypergol system test tool 9021279, or equivalent, from Hypergol System “g 917 Tool Kit G3135 must be used for this test. i CAUTION The hypergol system tool must be tested for proper operation prior to mount- ing on the hypergol assem- biy. ® Extreme care must be used when installing the hypergol system test tool, to prevent damage to the hypergol car- tridge follower. e@ Threads of the test tool cap must be clean and free of nicks, to prevent galling threads of the cap and inlet port. The heat exchanger LOX system must be blocked during this test. Thrust chamber protective cover, thrust chamber exit, oxidizer overboard drain line, and th ‘ust chamber throat closures must be removed during this test. yp uoTaas 13-96867H OLB t9quaydag § ~ g ‘ON aBULYD L9-T Require ments Limits Paragraph Activities 1.3.40A (cont} 1.3.40B THRUST CHAMBER PREFILi LINE LEAK AND FUN 2 ¥, : 2 Tt “ Special Constraints and Remarks ¢. Leak-test at 10 +1 psig No leakage is gaseous nitrogen, internal allowable. tubes between throat plug and thrust chamber exit Leak-test external thrust No prefili system chamber prefil] system external leakage is connections while pre- allowable, filling thrust chamber with ethylene glyco! solution. CAUTION During rernoval and installation of No. 1 and No. 2 fuel inlet manifold quick- disconnect caps. the quick-disconnect body must not be allowed to turn since damage to the quick-disconnect body can result. Perform this test after hy- draulic control system leak test, valve timing test, LOX feed system leak test, fuel feed system leak test, LOX dome and gas generator LOX injector purge leak and func- tion test, and tarust chamber fuel jacket flush. When this test is not being per- formed in conjunction with admitting prefil] to engine (paragraph 1,5, 10), hydraulic supply pressure to control system is not required pro- vided engine fuel feed system 18 Pressurized or drain hoses are installed on No. i and No. 2 fuel high-pressure duct quick-disconnects. [had a= ~ MA 900 TI-9686~-U J “oReag &9-T OLET Aavnaqod OF - g “ON oduEND Paragraph Activities 1.3.40B {cont} 1.3.41 THRUST CHAMBER PREFILL LINE LEAK AND FUNCTION TEST 13.414 IGNITION MONITOR VALVE POPPET POSITION VERIFI- CATION Requirements a. Perform external leak test of joints and fittings at 15 (-0, +5) psig gasecus mitrogen. b. Verify purge Now. No purge flow requires isolation test of prefill check valve. Verify by position switch indi- cation, for a minimum of 3 minutes, that fuel valves remain closed when hydraulre control system is pressurized to 1,500 -50 psiz, zero pressure 1s applied at ignition monitor valve CONTROL port, and engine control vaive start sclenoid is energized. Limits No external leakage 1s aliowable. Audible flow from thrust chamber exit, or by feeling prefill surply line Fuel valve closed posi- tion switches must remain on. Fuel valve open posttion switches must not come on. Special Constraints and Remarks Low LOX dome and gas genera- tor LOX injector purge must be on during filling and overflow operations of thrust chamber. ‘ OC Thrust chamber protective ? cover and thrust chamber exit and threat closures must be removed during this test. Perform this test prior to LOX dome and gas generator LOX injector flush, 1f per- formed, and after thrust chamber pneumatic leak test. A pressure of 40 +5 psig gase- ous nitrogen applied at the stage umbtlical is acceptable to perform leak test and purge flow. Thrust chamber exit and throat vlosures must be removed during this test. Leak-test compound must not be used on braided Mex line bellows. Perform this test subsequent to last application of gaseous nitrogen to ignition monitor valve CONTROL port and prior to static test or start of launch countdown. The operational low-level LOX come and gas generator LOX injector purge must be on if test is performed subsequent to LOX dome and gas generator LOX injector flush. Purge must meet requirements of section lI. 503 CAUTION The hypergol manvfold assembly cam rod must not be depressed during this test. 1 uojaas 11T-968€-H4 OLGI TWady gz - 2 ‘oN oduLYyD 69°T Paragraph Activities Requirements Limits 1.3.42 THRUST CHAMBER Leak-test internal and No thrust chamber LIQUD LEAK TEST external thrust chamber surfaces with trichlore- ethylene or ethylene glycol solutions. internal or external liquid leakage is dlowable. Specie! Constraints and Remarks Perform this test prior to thrust chamber injeclor visual inspections, and thrust chamber post- flush leak test and after hydraulic control system leak test, valve timing test, LOX iced system leak test, fuel feed system leak test, and LOX dome and gas generator LOX injector purge leak and function test. This requirement may be accomplished during per- formance of thrust cham- ber fuel jacket flush or admitting prefil! to thrust chamber, Hydraulie control system pressure of 1,530 =50 psig must be applied or drain. lines connected to fuel high-pressure %05 duct quick-discornects, or the engine fuel propellant feed systers pressurized to 2 psig minimum. Thrust chamber protective cover and thrust chamber exit and throat closures must be removed during this test. Dram hoses must be installed on No. Land No. 2 fuel high- pressure duct drain quick- @isconnects and monitored for leakage if fuel feed system is not pressurized during perform- ance of this activity. 902 T1- 9688-1 [ uoRag HL-T ZLGI Udy & - CE ‘ON aduey,y Paragraph Activities Requirements 1.3.43 THRUST CHAMBER Perform external leak test at POST- FLUSH 9 +1 psig gaseous nitrogen of all PNEUMATIC LEAK thrust chamber system joints TEST AT KSC invalidated during accomplishment of LOX dome and gas generator LOX injector flush and thrust chamber fuel jacket flush, except the thrust chamber fuel inlet manifold drain quick disconnects and the one LOX system joint used for accomplishing this test. Limits No emernal leakage is allowable. Special Coustraints and Remarks LOX dome and gas generator LOX injector flush, thrust chamber fuel jacket flush, heat exchanger LOX system leak test, and thrust chamber liquid leak test. CAUTION The thruct chamber must be pressurized from the LOX side and depressur- ized from the fuel or combustion zone side. Thrust Chamber Throat Plug G3136 and hypergol sysiem test tool 9021279, or equiva~ lent, from Rypergol System Tool Kit G3135 must be used for this test. CAUTION 930 The hypergol system too} must be tested for proper operation prior to mounting Perform this test prior to thrust chamber injector visual inspection and after | on the hypergol assembly. ® Extreme cace must be used when installing the hypergol system test tool, to prevent damage to the hypergol cartridge follower. ® Threads of the test tool cap must be clean and free of nicks, to prevent galling threads of the cap and inlet port, The heat exchanger LOX system must be blocked during this test. The oxidizer overboard drain line, and thrust chamber throat closures must be removed during this test. ] Woyaag Et -3686°H 2L6T 4940}00 6 - PT ON ABuLYD OL-1/VOL-T Earagraph Activitles STORAGE PREPARATION STORAGE PREPARATION FOR UNINSTALLED ENGINES Requirements Visuaily verify that all exposed and accessible portions of engine are not damayed. Coat all machined areas of thrust chamber outrigger arms, turbo- pump mounts, and inside and out- Side diameter of engine handler bearing with corrosion preventa- tive, Repaint all turbopump and outrigger arm surfaces that contain scratches. Remove any corrosion from gas generator feed line gimbal joint yokes; then coat yokes with cor- rasion preventative. Remove any corrosion from gas generator fuel and oxidizer feed line bellows. Verify or install 425 aluminum- foil tape {Minnesota Mining and Mfg) over space between thrust chamber exhaust manifold and thrust cham- ber tubes, and white sealant RTV-102 iGeneral Electric) be- tween thrust chamber tubes and bands. Replace or install any broken lockwire, and plug any open en- gine taps. Refill! any void in turbopump hous- ing cavity material. Determine if turbopump requires re-preservation; re-preserve turbopump (if required) and enter date in Enzine Log Book. erify that LOS pump and fuel inlet closures are installed and that desic- cant in closures is as specified in section ¥. Special Constraints Limits and Remarks Damage within limits of figure 1-3 White sealant is only required on engines where Sealant was in- stalled during engine manufacture. Kefer to section II Refer to Engine Log Book for for re-preservation date of last turbopump preser- hmuits. vation. 930 TT-968¢-4 J] UoVOaS ZLBT 4999700 g§ ~ PL “ON aBuRYD tL-l Special Constrains Paragraph Achyitios Require ments Limits and Remarks 1.4.1 k. Verify that thrust chamber throat 931 (cont) security closure is installed and that desiccant in closure is as specified in section II, i. Install Gimbal Bearing Locks G4059, 910 | 1A, Visually verify that oxidizer Residuai fluid is not overboard drain and nitrogen allowable. purge overboard drain line exits are free of fluid. ? a ; c > Lie iP aoe 1B. ‘Install protective closures on oxi- = dizer overboard Crain and aitrogen Ase . Ko, OF purge orerboard drain line exits, carta cee i i Saeed Se hypergoi container, and electrical connectors. All other covers and 950 closures except as noted in this 91¢€ step and in steps } and k are to be removed including the gimbal bearing boat and the fuel over- board drain line exit. IC. Install suitable drainage line on fuel overboard drain line exit, and route line exit so that leakage flows externally from engine. m. Install engine on Air Transport De not store engine in a position Engine llandler G4044, Engine where LOX pump elsvation is Handler G4069, or Engine Han- below fuel pump elevation by dling Dolly G4058, or equivalent. more than 7 degrees. n. Cover engine with engine cover G4047, or equivalent, except when engines are stored in accordance 930 with MSFC-STD-500, then install covers in accordance with MSFC-STD-500. o. Store engine in an environmentally controlled area meeting criteria specified in section T! or Standard §-IC Stage Storage Specification MSFC-STD-500, as appheable, 1.4.2 STORAGE PREPARATION a. Visually verify that all exposed Damage within limits FOR INSTALLED ENGINES and accessible portions of engine of figure 1-3 are not damaged, T1~969¢-U I uoy2ag hcl ZLBL 2990} G - $T ‘ON B2uKqD Special Constraints Paragraph Activities Requirements Limits and Remarks 1.4.2 b. Coat all exposed machined areas (cont) of thrust chamber outrigger arms, c. f. gs 1. turbopump mounts, and inside and outside diameter of engine handler bearing with corrosicn preventative. Repaint all turbopump and outrigger arm surfaces that contain scratches through paint. Remove any corrosion from gas generator feed line gimbal joint yokes; then coat yokes with corro- sion preventative. Remove any corrosion from gas generator fuel and oxidizer feed line bellows. Verify or install 425 aluminum- foil tape (Minnesota Muining and Mfg) over space between thrust chamber exhaust manifold and thrust chamber tubes and thrust chamber, and white sealant RTV-102 (General Electric) between thrust chamber tubes and bands. Replace or instalf any broken lockwire, and plug any cpen engine taps. Refill any voids Preserve turbopump as outlined ‘Turbopump preservation must PRESERVATION in paragraphs 1.5. 22.2 or be performed with engine or 1,5.22.2, as applicable. stage in vertical position. CAUTION During engine or stage rotation, tae LOX yung must not be allowed to be iower than the fuel pump inlets by more than 7 degrees since con- tamination of the LOX pump could occur. Preserve turbopump within limats of section II. Following an abort preserve turbopump only if fuel was introduced into bearing cool- ant controi system. 1.5.22.1 Turbopump Preservation a. Provide instrumentation or instrument range, (Bagines Not Incorpo- pressure gage to measure 0-250 psig raung MDis5 Change} pressure at tap LBtb. TT -9686 -U J NOyIAS OLGL Foquaylus G - g *ON SBuRYD c6~t Paragre ph Activities grep 1.5.2.1 be. (eant! Turbopump Preservation ik f (Engines Incorporating MD149 Change} Requirements Limits Cennect gasevus nitrogen purge line to bearing covlant c centro! vatve PRESERVATIVE N port. Pressurize bearing coolant cuntroi valve, and purge for 5 minutes, 35 -10 psig Preservation supply must meet requirements of sectiun TH. Discenaeet purge line, and connect preservative supply to PRESERVATIVE IN port. Slowly rotate turbopump one revalut:on minimum, and supply a@ mininien of 5 gallons of pre- servaive oul to turvopump bear Wys. Aliow turbopump to drain for 135 minutes menimuem. Disconnect preservative supply 35 210 psig lane. and reconnect purge line to bearing covlant curtroel valve PRESERVATIVE IN port. Purge tuebopump hearings for 5 minutes. Record turbopump re-preserva- tron date in Engine Leg Beok. oe istrumentation or rossure vue to measure pressure at cap LBib. Instrument range 0-iCS psi Disconnect turtine bearing lube Crain hose from fuel drain mani- fold, and vacuum fluid fror turbine bearing lube drain hose, Special Constraint: and Remarks Exit closure must be removed from oxidizer and fuel over- board drain lines. Pressures 1 iisted in i:mits column are as measured at tap LBIb. Turbopump LOX pump seal puree miust be on and meet requirements of section Ii before and during perform- ance of this activity. Perform requirements in sequence listed. One revolution of the turbo- pump shalt requires 3 revo lutions of the terque pinion gear. The locking pin and turque pinion gear must be fullv extended after turbo- pump rutaties 1s conipleted. Re-preserve Cuarbopump if gaseous aitrogen pressure axceeds 50 noig at any time, The scavenze pun np G2038 or equivacent, wnust be used for ths activity. an _ = IT- 968€-H J ROTPIAg F6-T OLGL Taquudydag § - g "ON OSUID ——_———— eee Paragraph 1.5,22.2 (co1.t} Activities ee h. i. kK. Reduirements ‘Jeleted} Con:ect gas*ous nitrogen purge zine to Sea” olay control valye f° TIVE IN port. Slow ay trot. vre@ssure and purge fulocyump bearings through PRESERVATIVE IN port for 1-2 minutes. 5-10 psig Disconnect purge line, and connect preservative supply to PRESERVATIVE IN port. (Deleted; Vacuum fluid from turbine bearing lube drain hese when per.ormung Steps} throvgh «. Slowly rotate turocpump one revolution minimum, and supply a minimum of $ gallons of pre- servative oul to turboounip bearings. 80 =10 ps: qa Discontinue turbopump rctation, and stop oil flow to turbopunip bearings. Vacuum fluid from turbine bearing lube drain hose until fluid flow ceases. Disconnect vacuum system, and reconnect turbine bearing lube drain hose to fuel drain manifold. Disconnect preservative supply, and connect 2 gaseous murogen purge line to bearing cvolant control yalve PRESERVATIVE IN port. Slowly increase pressu.e and purge turbopump bearings through bearing coolant control valve PRESERVATIVE EX port for 5 minutes. 5-10 psig Limuls Preservation supply muSt rieet requirements of section I, — Special Constraints and Remarks Exit closures must be removed from oxidizer and fuel over- board drain lines. Pressures listed in limits column are as measured at tap LBIb. ‘Ine furbopump LOX pump seal purge must be on and meet re- quirements of section II before and during the performance of this activity. Perform requirements in requence listed, One revolution of the turbopump shaft requires 5 revolutions of the torque pinion gear, The lecking pin and torque pinion gear must be fully extended after turbopump rotation is competed. Re-preserve turbopumip if gaseous nitrogen pressure exceeds 50 psig at any time. 614 — 8 a ] votas TE -968E - 2 TL6U ABW 9 - IT ‘ON aaveyd 96-1T/S6-T Paragraph Acuvities 1.5.22.2 (cont) 1.5.23 and (Deleted) 1.5.24 1.5.25 FUEL FEED SYSTEM DRAIN SUBSEQUENT TO STATIC TzeST ABORT 1.5.26 (Deleted) through 1.5.29 Pages 1~96A through 1-96D deleted, Requirements ni. Record turbopump represerva- tion date in Engine Log Book. a. Connect drain hoses to the fol- lowing quick-disconnects: \14) Turbopump fuel inlet No. 1 (2) No. 1 and No. 2 fuel high- pressure duct (3) Gas generator bail valve fuel inlet drain b. Allow all fuel to drain. c. Remove drain hoses and rein- stall and torque caps on quick-disccnnects. Speci) Constraints vnd Renuirks Perform prior to draining thrust chamber fuel jacket and fas generator cumbustor. The F-1 Fuel Orqin Vent Adapter Kat 99-9012908 mus: be installed during this ac- tivity uf stage fuel pre-valves are closed. Prior to draining fuel, very that the fotlowing conditions exist: {1) (Deleted) (2) Hydraulic controi syste: 18 pressurized within limits of section LU. \8) Engines are in a null positzon. CAUTION During removai of the gas generator bal! valve fuel inlet drain quick- Cistennect cap, tne quick-disconnect body must not be allowed ta rn. Use care while draining fuel to prevent spulage on other engine systems. aye 11-969e-U ] Woyas TL6¥ AVING ~ IT “ON o3ueUD 86"T/L6-1 Special Constraints Paragraph Actrvitles Requirements Limiis and Remarks 1.6 HANDLING 16.1 ENGINE INSTALLATION a. Verify that the following gimbal CAUTION AT MAF wrap-around lines are instalied, in- Vie e stailed w.thin limits of alinement Fore:gn matter must not tool T-5041232. and supported with be allowed to enter turbo- F-1 wrap-around Hies support set pump LOX and fuel inlets T-5046440 to preclude line movement: since forciga matter will contaminate the turbo- (1) Hei.em suppiy duct pump and contamination may necessitate exten- (2) Hetium return duct sive turbopump repair. (3) GOX return duct (4; Hydraulic supply duct (5) Hydraulic return duct (6) LOX dome purge hose (7) Turbopump LOX seal purge hose (8) Thrust chamber jacket prefill hose (9) Coevon purge hose b. Remeve cuvers, and inspect turbo- No foreign matter prmp oxidizer and fuel inlets for is alluwable in foreign :natter. Remove desic- inlets. cant from covers, and store des- iccant as specif.cd in section Il, c. Immediately after inspection of inlets, cover inlets with Aclar No. 33C film (6. 002-inch minm- mum thickness) (Allhed Chemical Corp) and secure with pressure- sensitive tape RBO195-002 (Rocketdyne), or equivalent. d. Before installing engine, remove CAUTION gimbai boot cover and make sure that 4 Gimbal Bearing Locks G4i059 The engine must be and electrical cable support post ammobil:zed with {outboard engines only) are installed. Stage Contractor sup~ pled gimbal actuator locks. I Wotjoos TI-9886-U 86-1 Paragraph 1.6.1 {cont} 1.6.2 Activities THRUST CHAMBER NOZZLE EXTENSION INSTALLATION i. je Require ments After installing engine, remove 4 Gimbal Bearing Locks G4059. Reinstall gimbal boot on gimbal bearing. Remove Aclar film from turbo- pump LOX and fuel inlets, and connect stage ducting to inlets. Connect interface electrical connectors, Connect stage pressure switch checkout supply line to fitting on engine interface panel. Connect the following gimbal wrap-around ducts and hoses to stage using Stage Contractor supplied installation criteria: (1) Heliuwa supply duct (2} Heliuro return duct {3} GOX return duct (4) Hydraulic supply duct {$) Hydraulic return duct {6} LOX dome purge hose (7) Turbopump LOX seal purge hose {8} Thrust chamber jacket prefill hose {9} Cocoon purge hose Using Engine Vertical Installer G4049, position nozzle exteusion beneath thrust chamber exit and aline index mark on nozzle exten- sion with index mark on thrust chamber exhaust man:foid flange. Limits Special Constrarmnis and Remarks Perform after completion of exhaust system leak test. Engine must be in null position. Prior to installation, verify that thrust chamber nozzle extension serialnumber is same as that listed in Engine Log Book. Tt-9688-U ] uoTpas oot-t OLB Jaquwadaq @ - § “ON eduLyy Paragraph 1.6.2 (cont) i. 6.3 Activities IGNITER HARNESS INSTALLATION b. c. f Requirements Clean nozzle extension attach flange seal groove and flange bottholes with drycleaning solvent, Or equivalent. On engines incormorating MD135 change, mspect seal for joint overlap. Install and visually determine that nezzle extension seal is seated in nozzle extension se€al groove, Elevate nozzle extension 50 that flange is between 1/8 and 1/4 inch of thrust chamber attach flange, Install and torque nozzle ex- tension to thrust chamber exit flange fasteners, On engines incorperaring MD135 change, retorque all fasteners an additional 2 tumes at one-hour intervals after initial torquing. Lower Engine Vertical Installer G4049- Install oxidizer, nitrogen purge. and fuel overboard drain lines. Route and clamp harness to thrust chamber. Limits 0. 060- to 0. 030-inch free-state thickness for square-cut lap joints having approx- imately one inch of overtap. Specral Constraints and Remarks WARNING Drycleaning solvent is flammable and musi not be used near heat, sparks, or open flame. Inhalation of its vapors or proionged contact with the liquid can cause serious injury to person- nel. CAUTION Nozzle extension flange must not be allowed to contact thrust chamber exit flange during ele- vation of nozzle exten- sien since flange dam- age may result. Start bolt installation at index mark hole and continue around periphery on both sides or either side of index mark. Use Nozzle Extension Aline- ment Tool O4078 to aline boli- holes or drift pins, if neces- sary. Perform prior to igniter installation and igniter har- ness checkout. ] Woyoag 11-9888 - 4 OL61 oquiazdag g - g ‘uN aBuBYyD TOr-t Special Constraines Paragraph Activities Requirements Limits and Remarks 1.6.3 b. Connect igniter harness plug (cont) P47 to receptacle Ji7. Terque and safetywire plug to receptacle. 1.6.4 THERMAL INSULATIO“ a. Perform torque check of Torque-check every tenth Perform after completion of INSTA nozzie extension flange fasten- fastener. If any fastener all other listed requirements ers just prior to installing is not within limits, re- for vehicle checkout at VAB thermal insulation, which re- torque ail 240 fasteners. except engine environmental stricts access to flange. cover installation. Record results. b. Remove protective covers from propellant high-pressure ducts. ec. Remove al! engine covers and closures that will be enclosed by thermal! insulation. d. Install thermal insulation. 1.6.5 ENGINE ENVIRONMENTAL Install cover on engine with silver- Install cover after thermal COVER INSTALLATION colored side of cover on inside sa insulation installation and that overboard drain lines are ex- before vehicle movement to posed through holes provided in launch complex. cover andaccess to igniter ports ox "ozzle extension is not re- stricted. 1.5.6 HY PERGOL CARTRIDGE a. Wipe hypergol protective WEIGHT CHECK tusu protective packaging plastic bag free of contami- (both bags if double packaged) nants with a lint-free cloth is not allowable. Restoration moistened with trichloaro- of hypergol cartridge to a ethylene; then remove hyper- serviceable condition must gol cartridge from plastic meet requrements of protective packa:'ing. section II. b. Compare current gross Current gross weight Perform prior to hypergol weight of hypergol cartridge must be within 15 grams cartridge installation. with gross weight recorded of recorded gross on hypergol cartridge. weight noted on hypergot CAUTION Record results. cartridge, The hypergol cartridce must be protected from gamage and contamina- tion until installed in hypergol container. TT S686 -U I vapay ZOT-t OLGL T9Quiacag 2 - G “ON a2uEND 4 a ° 5 oo Paragraph 1.5. an Activities IGNITER INSTALLATION eee C TEST AND sAUNCH t—“‘“ CSCSC*™S# Requirements Verify that expiration date noted on hypergol cartridge 1s not ex- ceeded. Verify (by hand-torquing in toghtening direction) that hypergol cartridge is tight to its plug. Inspect packings for chipping, cracking, or improper fit, and verify that downstream ring is not tucked under packing. Repackage and store hypergol cartridge as specified in section Tl until ready for instalation, Visually inspect that gas gen- erator and nozzle extension igniter ports are clean of car- ben and other loose particles. Verify that igniters have been tested as specified in paragraph 1.2.9, Visually inspect each igniter prior to installation for. (1) Closure damage (2) Thread damage (3) Bent or loose receptacle pins (4) Nicked or scratched gasket or gasket seating surfaces (5) Six-month time excecded Since igniter was removed from container Special Constraints Limits and Remarks WARNING Fluid leakage froma damaged hyvergoi car- tridge can result in seriovs injury to per- sonnel and damage to equipment, Use of hypergol car-~ tridge that has ex- ceeded expiration date 18 act allowable. Damage to packings ts not allowable. Res- toration of hype: gol cartridge to a service- able condition must meet requrements of section II. No contamination ts allow- able. No damage 15 allowable. No damage is allowable. No damage 15 allowable. No damage .s allowabie. 912 916 I uayq2a¢ It -g6ge - 8 OLET T9qQUis09q Z - § "ON osutYD car-T Special Constraints and Reniurks No lubrication 1s at:uwable on igniter thren 10g cartridge removal, LOX dome and gas generator i § LOX injector flush, and LOX dome flush. 2.1.2.8 Hypergol Malfunction Purge System Requirements. a. Fluid specification: gaseous nitrogen (MIL-P-27401; b. Fluid supply filtration requirement: 40- micron (or finer) filter having a maximum pore size of 100 microns ce. Fluid temperature: 0° to [130° F d. Pressure; 700-800 psi e, Sequencing: required for live hypergol 8 Gn F aw cartridge removal. Section IT Paragraphs 2.1.2.6 to 2.1.3.1 2.1,2,9 igniter Fuel Valve Lockup Require- nents. = a. Fluid specification: gaseous nitrogen (MIL-P-27401) b. Fluid supply filtration requirement: 40- micron (or less) filter having a maximum pore size of 100 microns c. Fluid temperature: 0° to 130° F d. Pressure: 725-775 psig (static pressure, no flow) ec. Sequencing: required for live hypergol cartridge removal. 2,1.2,10 Turbopump Preservation Servicing Purge System Requirements. a. Fluid specification: gaseous nitrogen (MIL.- P- 27401) b, Fluid supply filtration requirement: 40- micron (ur finer) filter having a maximum pore size of 100 microns c. Fluid temperature: 0° to 130° F d. Pressure: (1) Engines not incorporating MD145 change: 25-45 psig (2) Engines incorporating MD145 change: 5-10 psig e. Flowrate: (1) Engines not incorporating MD145 change: 0.01 lb/sec at 35 psig (2) Engines incorporating MD145 change: 0,003 Ib/sec at 7.5 psig 6th f, Sequencing: required for turbopump preservation. 902 2.1.8 HEAT EXCHANGER REQUIREMENTS, a Alert a. Heifum specification: Bureau of Mines, Grace A Change No, § - 2 December 1370 2-3 Section Ii Paragraphs 2.1.3.2 to 2.1.5 b. Helium supply filtration requicement: 40-micron (or finer) filter having a maximum pore size of 100 microns c. Helium Inlet prescsure-temperature: -400° to +130° F at a pressure not exceeding 400 psig d, Flowrate: 1.00 lb/sec maximum e. Sequencing: Stage Contractor responsi- bility rr gt ae LD Conditions. a. Helium outlet pressure-temperature: -400° to 4500° F at a9 pressuie not exceeding 325 psig b. Helium flowraie: 1.00 lb/sec maximum c. Helium transient pressure surges: surges nol exceeding 400 psig d. Sequencing: Dcpends on paragraph 2.1.3.1 sequencing. 2.1.3.3 Heat Rxchanger GOX Oulpul Conditions. a. Fluid specification: heated GOX (MIL- P- 25508) b. Fluid cleanliness: (1) Maximum particulate matter size: 200 microns (2) Maximum soluble hydrocarbon content: 75 ppm (3) Maximum acetylene content: 1-1/2 ppm c. GOX flovrate: 3-151b/sec d, GOX throtUe Limits: Flowrate must not be throttled be,ow 3 lb/sec. e. GOX temperature: 400° to 500° F at en- gine interface with flowrate at 4 lb/sec f, GOX pressire: 1,360 psig nominal dis« charge pressure g. Sequencing: Heated GOX 1s supphed within one second after engine control valve R- 3896-11 start signal, and flow terminates 0.75 second maximum after engine control valve stop signal. 2.1.4 OXIDIZER FEED REQUIREMENTS. a. Fluid specification: liquid oxygen (MIL~P- 25508) b. Fluid cleanliness: (1) Supply filtration requirement: 70- micron (or finer) filters having a maximum pore size of 200 microns (2) Maximum soluble hydrocarbon content: 73 ppm {3} Maximum acetylene content: 1-1/2 ppm c. Nominal fluid flowrate: 3,950 lb/ser d. Fluid pressure-temperature: within limits specified in figures 2-2 and 2-3 e. Supply transient pressures: Maxirnum allowable static pressure surge must not exceed 335 psig, f. Pressurizing media: The following Muids may be used to prepressurize and to pressurize the oxidizer propellant: (1) Gaseous nitrogen (MIL-P-27404) (2) Gaseous oxygen (MIL- P-25508) (3) Helium (Bureau of Mines, Grade A) g. Sequencing: Liquid oxygen must be supplied to the oxiclizer pump inlet a minimum of 90 minutes prior to engine control valve start signal, The stage-provided oxidizer pre- ‘alve must be sequenced to the closed position after a time delay that allows the engine oxidizer yalves to reach the closed position, 2.1.5 FURL FELD REQUIREMENTS. a. Fluld specification: RP-1 fuel (MIL-R - 25576) b. Fluid supply filtration requirement: 70- micron (ur finer) filters having a maximum pore size of 200 micrans c, Nominal fluid flowrate: 1,750 1b/sec d. Fluid pressure-femperature: within mits specified in figures 2-3 and 2-4 R-3896-1i Section II Os a eg tL t | | Aude | 280 ork axa = ;) | ‘ | Bog rst SELESS TT OP MT 0O re ee ee ae cepemed ORO OE Ae Or kage ALS 16 =300} - ——- + see -4 ~ ee et wee i aod ie an C] PRE START 4| 1) [7] OPLRATING =f | ce | -nol sa i eR ae Ee io 40 co ar) 100 120 140 tuo To OXDDIZER P* MP IXLET PROPELLA..T FEMPFRATURE CF Bred) ERA — Figure 2-2. LOX Pump Inlet Conditions —— reir iy aon LL lL I tt Pre oe (PSLA = o i I | RE : ie 140 160 160 PRE-START FLEL PL MP INLET PRC PELLANT PRESS YRE-START OXIDIJEM PUMP INLET PROPELLANT PRESSURE (Pst) FL II-194 a Ee er YL rere ne PEN ty Figure 2-3. Acceptable Pump Inlet Pressures Section IT Paragraph 2.1.6 -— 14?) R-3896- 11 100 60 60 en tn et ee a — x j PRE-START FLEL PUMP INLET PROPELLANT TEMPERATURE f F) TOTAL FURL PUMP ISLET PROPELLANT PRESSURE (VSIA) Figure 2-4. ce. Supply transient pressures: Maximum ilo, able static pressure surge must not exceed 380 psig. f. Pressurizing media: Gaseous nitrogen (MIL-P-27401) or helium (Bureau of Mines, Grade A) may be uscd for prepressurization and pressurization of the fuel propellant. g. Sequencing: Fuel must he supplied to the fuel pump inlets a minimum of 60 minutes prior to the engine control valve start signal. The stage-provided fuel pre-valves must be se- quenced ta the closed position after a time de- day Uldt alLuws the engine fuel valves to reach the closed position and after the stage-provided oxidizer pre-valve has reached the closed posi- tion. 2-6 | YARDS LL YY BI-TT-20A4 “uel Pump Inlet Conditions begs Pyreap? a fethe; rr rrr EERE . 2. ie) HYDRAULIC GROUND SUPPLY RE- QUIR a a Fluid specification; RP-1 fuel (MIL-R-25576) oc RJ-~1 fuel (MIL- F-25558) b. Fluid supply filtration requirements: 10- micron (or finer) filter having 2 maximum pore size of 25 microns c. Fluid flowrate: Fluid must be supplied to the engine connect point at a nominal steady- state flowrate of 12 gpm with a transient flow- rete of 35 ppm. dd. Fiuid temperature: 35° to 130? F with no liquid oxygen in engine propella. . feed system and 60° to 120° l with liquid oxygen in engine propellant feed system, you sient fae (including R-3896- ° Bleeding: The engine hydraulic control system must belied of entrapped air before enersizing the engine control valve start solenoid after initial application of hydraulics 909 to the engine and any time thereafter that hydrauhe system is invalidated by drainage. Entrapped air can be removed by circulating: hydraulic fluid through the system at 1, 000 psipz (minimum) for a period 15 minutes (minimum). f. Operating pressures: The hydraulic con- trol system pressure must be supplied tu and removed from the engine in such a manner as to preclude the possibility of the return pres- sure exceeding the supply pressure. Pressures are as follows: (t) If fuel valve teakave occurs withcut the hydraulic control system pressurized, hydraulic pressure stcadyv-state limits must be maintained oetween 416 and 1,850 psig, and pressure tran- surges resultype from pambaling) between 419 and 3, 000 pei must be maintamed at all ¢imes fuel or prefill is in the Cheine without drain hoses installed on thrust chamber fuel mlet manifold drain quick-dis- connects. (2) During and after LOX admittance to the engine but prior tu checkout valve actuation ty the engine position during engine startiny, hy- draulic pressure steady-state limits must be maintained vetween 1,450 and 1,850 psig, and transient pressure surges (including surges resulting from gimbaling) between 415 and 2,000 psig. (3) During engine starting prior to check- out valve actuation to the engine position. hy- draulic pressure Btoady ts e limits must be maintained between 1, 450 and 1, 650 psig:. (4) During engine starting, hydraulic pres- sure as measured at the engine eontrol valve must not decrease below 900 psiv or remain below 1,200 psig for a time period in excess Of 40 milliseconds. f. In the event fuel is loaded on the stage with the stage Pee closed, anda minimum of 415 psig hydraulic control pressure is not applied to the engine, drain lines must be in- stalled on either the No. 1 and/or No. 2 fuel yemp inlet drain quichk-disconnect and the drain ine must be monitored for fuel pre-valve leakage. 2.1.7 PREFILL SUPPLY REQUIREMENTS a. Fluid specification: ethylene glycol RBO0210-017 (Rocketdyne) b. Fiuld cleanliness: The solution must be colorless, clear, and free of sediment. ec. Fhid flowrate: 10-20 gpm Section II Paragraphs 2.1,7 to 2.1.8.1 1k d, Fluid pressure: 20-40 psig e. Fluid temperature: 0° to 130° F f, Composition: distilled or deionized water conaining 50 ¢h percent by weight of ethylene glycol gy. Acidity: pH of solution, 6.5 +1.5 h. Specific gravity: 1.0640 :0,0015 at 26° C i. Flash pojnt: must not flash » Gallons required: approximately 105 gallons not including overflow 2.1.8 FLUSHING SOLVENT SUPPLY RE- QUIREMENTS. Injector Flushing System Requirements. a. Solvent specification: trichloroethylene NBV210- 003 (Rechketdyne) free of sediunznt and suspended matter. Alternate solvents that may be used are as follows: (1) Trichloroethylene (MIL-T-27602) or MB02 10-003 (North American Rockwell Corp, Space Division) may be used as a LOX dome and gas penerator LOX injector flushing agent pro- vided a minimum of 48 hours ts allowed to elapse between engine flushing and engine firtug. (2) Trichlornethylene (Federal Specifica- tion O-T-634, Type I) may be used as a LOX dome and gas genera.or LOX injector Dushing agent provided it has passed the residue-soluble- in-carbon-tetrachloride test of MIL-T-27602 or RBO2 10-003 (Rocketdyne) and a minimum of 48 hours is allowed to elapse between engine flush- ing and engine firing. (3) Trichloroethylene (MSFC-SIPUC-217) may be used as a LOX dome and gas generator LOX injector flushing agent provided it has passed the residue~soluble-in-carbvon-tetra- chloride lest of MML-T-27602 or RB0210-003 (Rocketdyne) and a minimum of 18 ‘ours is allowed to elapse between engine flushing and engine fring. Change No. 7 - 28 April 1970 a~% Ol’ Section I] Paragraphs 2.1. 8,2 ty 2.2, 2 b. Selvent must be supplied to Oxidizer Dome Flushing Kit G2030 installed on the en- vine as shown in figure 2-5 and as follaws: (1) Flowrate: (2) Pressurc: 80-100 psig (3) Temperature: O° to 130° F 2.1,8.2 Thrust Chomber Fuel Jacket Flushing Requirements, 9.9 gpm nominal a. Solvent specification: (1) Trichloroethylene RB0210-003 (Rocketdyne) (2) Trichloroethylene MB0210-003 (Nerth Ainerican Rockwell Corp, Space Division) (3) Trichloroethylene (Federal Speeifiea- tion O-T-634, Type 1) (4) Trichloruethyiene (MSFC-SPEC- 217) (5} Trichloroethylene (MIL- T- 27602) b. Fluid cleanliness: free of sediment and suspended matter ¢. Salvent must be supplied to the two thrust chamber fuel inlet manifold quick- disconnects for thrust chamber fuel jacket flushing as follows: (1) Flowrate: 10 gpm nominal (2) Pressure: 80-100 psig (3) Temperature: 0° to 130° F 2.1.9 PRESERVATION FLUID SUPPLY QRE- QUIREMENTS. A system must be provided to Supply a minimum of 5 gallons of preservative fluid for turbopump preservation meeting the following requirements: a. Fluid specification. corrosion preven- tive MIL.-C-14201, Grade 2. ‘he only accept- able alternate is corzosion preventative RBO0210-016 (Rocketdyne). b. Fluid cleanliness: supply filtration re- quirement of a 74-micron (or finer) filter during recirculation and a 40-micron (or finer) in-line filter during delivery to the turbopump. c. Nominal fluid flowrate: 4.7 gpm at 200 pois (on engines incorporating MbI45 change, ~2 gpm at §0 psig) sles d. Fluid a (monitored at instrumen- talion tap LB1b): 175-225 psig (on engines incorporating MD145 change, 70-90 psiy) ec. Fluid lolipe nature: 70° to 9£° F during {Inid recireulation and delivery to turbopump f. Mixing rcquivement: fluid recirculated a mininim of 10 minutes prior to Huid delivery to turbupump bearings 2-% Change No, 8 - 9 September 1970 R-3896- 11 #. On engines incorporating MD145 change, a suction pump is required with a flow capability of 2-8 gpm. 2.1.10 CORROSION- PREVENTIVE REQUIRE- MENTS. a. Fluid speeifications: (1) Unpainted working surfaces: lubricating vil (Federal Specification VV- L- 800) (2) Unpainted stationary surfaces: corrosion-preventive compound (MIL-C- 16173, Grade 1) or corrusion preventative RBO210-016 (Rocketdyne) b. Mixing requirement: Corrosion preventa- tive RBO210-016 (Rocketdyne) must be theroughly mised at 70° to 95° F immediately prior to each application. 2.2 ELECTRICAL INPUT REQUIREMENTS. 2.2.1 AC POWER REQUIREMENTS. a. Control system requirements: (1) Turbuepump heater No. ft: 190-220 vac. {0 eps, 1,500 watts maximum toad (2) Turbopump heater No. 2: 190 220 vac, 60 cps. 1,500 watts maximum load (3) Igniters: 500-750 vac, 60 cps, 10,000 wattS maximum load b. Instrumentation system * equirements: (1) Turbopump rpm transducer; 5 to 7.5 vac, 200 cps, 0.2 watt maximum load for ground checkout (4) Oxidizer flowmeter: 5 to 7.5 vac, 200 cps, 0.2 watt maximum load for ground check- out, 2.2.2 DC POWER REQUIREMENTS. Contro! system requirements: (1) Voltage level: 24-30 vde under load conditions until 0.5 second after completion of start sequence, and 20-30 vde thereafler pro- viding a maximum of 80 watts for 0.100 second and §5 watts thereafter for engine shutdown. le (2) Ripple voltaee: 1,5 volts maximum when measured with a peak reading vacuum tube voltmeter connected in series with a 40-micro- farad capacitor. The higher of the two values measured when the voltmeter is successively connected for cach of the two polarities is de- fined as ripple voltage. « 906 R-3896-11 Section II 2t 220 «2120 19 «18 view A LEGEND 1 TRICH PORT ‘B HOSE R3806- 12-0500 15 NO. 5 0900 FORT 2 GN2 PORT 9 HOSE 11806- 12-0600 ig NO, 2 1000 rORT 3 DURGE 15 PORT 10 PURGE NO. 3 PORT '7T NO. 10500 PORT REDUCER ANBI9- 15C UNION AN815 12° 1B HOSE H38c6- 12-0800 SEAL i210°CR8 SEAT 12100CR12 19 ADAPTER 9022109 4 PURGE LA PORT Tl PURGE 20 PORT 20 TAP GFBA REDUCER AN919-15C REDUCER ANBi9-15C DIFFUSE 9029994 SEAL t2101CR8 SEAL, 12100CRB 21 HOSE 19-9024938- 11 5 ADAPTER 0024153 12 FURGE 2A PORT 22 TAP GF 2b 6 HOSE R1B06-12 1084 REDUCER AN919 15¢ DIFFUSER 9023034 7 PURGE NO. 4 PORT SEAJ, 12100°'RO 23 ADAPTER 9625254 UNION ANSI '=125 13 ADAPTER 9024153 24 NO, 3 (600 PORT SFAT, 127000212 14 HOSE R3800- 12. 1000 25 NO. 4 1080 PORT 1-81-2348 ed YTS Bie a Yat rE Wigure 2-5. Oxidiazer Bome Flushing Kit Installation 2-9 Section TI Paragraphs 2,2A to 2.24.2 (3) Maximum voltage transient Umits: 50-volt positive pulse with a time width of 10 microseconds and a repetitive rate of 20 pulses per second (4) DC control system power requirement: 952 290 watts maximum b. Instrumentation system sequirements: (1) Circuit separation: Separate circuits nuust be provided for pressure transducer power, valve position power, electrical simu- lation circuits (except for turbopump speed and heat exchancer flows), and all resistance-type temperature transducers, (2) Pressure transducer and simulation circult voltage level: 24-32 vde, Continuous maxlnum application of 30-32 vde must not ex- ceed 60 seconds. (3) Pressure transducer and simulation circuit ripple voltage: 0.1 volt maximum when measured with a peak reading vacuum tube volt- met.r in series with a 4. 0-imicrofarad capac- itor. The higher of the two values measured when the voltmeter is successively connected for cach of the two pularities is defined as the ripple voltage. (4) Pressure transducer and simulation circuit maximum voltage transient limits: 50- volt positive pulse with a time width of 10 intcro- seconds and a repetitive rate of one pulse per second (5) Temperature transducer power require- ment: 100 microwatts maximum for each trans- ducer (6) Valve potentiometer voltage and power levels: 4.99 to 5.01 vde, 0.50 watts maximum (7) Valve position switches voltage and current levels: 24-32 ydc, one ampere maxi- mum (8) Potentiometer circuit ripple voltage. 0.025 volt maximum when measured with a peak reading vacuum tube voltmeter connected in series with a 4.0-micrufarad capacitor. The higher of the two values ineasured when the voltmeter is successively connected for each of the two polarities is defined as ripple voltage. 2-10 Change No. 14 - 9 October 1972 R-3896-11 2,2A ENGINE REQUIKEMENT'S ON STANDBY STATUS. — 2,2A.1 STANDBY STATUS DEFINITION, Standby status is defined as the time period that uninstalled flight spare or installed engines wait for the next authorized activity to start. These engines are not in storage, per MSFC-STD-500, UNINSTALLED 2.2A,2 PREPARATION OF ENGINE FOR STANDBY ST ATUS, a. Visuaily verify that all exposed and acces- sible portions of engine are not damaged. Dam- age, ifany, must be within limits specified in section |, b. Coat all machined areas of thrust chamber outrigger arms, turbopump niounts, and inside and outside diameter of engine handler bearing with corrosion preventative, ec. Repajint all turbupump and outrigger arm surfaces that contain scratches. d, Remove any corrosion fom gas generator feed line gimbal joint yokes; then coat yokes with 950 corrosion preventative. e. Remove any corrosion from gas generator fuel and oxidizer feed line bellows. f. Verlfy or install 425 aluminum-foil tape (Minnesota Mining and Mfg) over space between thrust chamber exhaust manifold and thrust chamber tubes, and white sealant RTV-102 (General Electric} between thrust chamber tubes and bands, White sealant is only required on engines where sealant was installed during engine manufacture. g. Replace or install any broken lockwire, and plug any open engine taps. h, Refill any void in turbopump housing cavity material, i, Determine if turbopump requires re- preservation; re-preserve turbopurp (if required) § and enter date in Engine Log Book. Refer to paragraph 2.4.11 for re-preservation limits anc to Engine Log Book for date of last turbopump preservation, Section Tl j. Verily that LOX pump and fuel inlet closures are installed and that desiccant in closures is as specified in paragraph 2,3.6.2, k. Verify that thrust chamber throat closure ts installed and that desiccant in closure is ag specified in paragraph 2.3.6.2, lL. Install Gimbal Bearing Locks G4059, m. Visually verify that oxidizer overboard drain and nitrogen purge overboard drain line exits are free of fluid, n. Install all protective closures except for fuel overboard drain line exit, o, Install suitable drainaye line on fuel over- board drain line exit, or drain bag, and route line exit so that leakage flows externally from engine. p. Install engine on Air Transport Engine Handler G4044, Engine Handler G4069, or Engine Handling Dolly G4058, or equivalent. 930 H 86g. 4 Cover engine with Engine Cover G4047, or equivalent, r, Place engine in an environmentally con- 7 trolled arca meeting criteria specified in f paragraph 2.3.1. Do not place engine ina B position where LOX pump elevation is below fuel pump elevation by more than 7 degrees, 2.24.3 PREPARATION OF INSTALLED ae = f ENGINES FOR STANDBY STATUS. I sible portions of engine are not damaged, ‘n section I, hb. Coat all exposed machined areas of ; thrust chamber outrigger arms, turbopump mounts, and inside and outside diameter of # engine handler bearing with corrosion preven- | tative, c. Repaint ali turbopump and outrigger arm surfaces that contain scratches through paint. R-3896-11 a, Visually verily that all exposed and acces- Ofgace . gee Be Damage, ifany, must be within limits speeified Section If Paragraph 2.24,3 ad, Remove any corrosion from gas generator feed line gimbal joint yokes; then coat yokes with corrosion preventative. e. Remove any corrosion from gas generator fuel and oxidizer feed line bettows, f, Verify or install 425 atuminum-foil tape (Minnesota Mining and Mfg) over space hetween thrust chamber exhaust manifold and thrust chatnber tubes and thrust chamber, and white sealant RTV-102 (General Electric) between thrust chamber tubes and bands. White sealant is only required on those engines in which seal ant was installed during engine manufacture, g Replace or install any broken lockwire, and plug any open engine taps. h, Refill any voids in turbopump housing cavity tiller material. i, Determine if turbopump requires re- preservation; re-preserve turbopump, if required, 70 and enter date in Engine Log Book, Refer to paragraph 2,4,11 for re-preservation limits, Refer to Engine Log Book for date of last turbo- pump preservation. j. Install desiccant in thrust chamber throat security closure as specified in paragraph 2.3.6.2. | k, Jnstall thrust chamber throat security closure, 1, Visually verify that oxidizer overboard drain and nitrogen purge overboard drain line exits are free of fluid, yet! we UG mh, -For engines installed in a horizontal stnge, ~~ perform the following: (1) Install all protective closures, (2}' Remove and replace fuel overboard drain system bags with drain hoses, and coute hoses 6o that leakage flows externally from engine, Change No, 14 - 9 October 1972 2-his 50 actuators to prevent engine movement, Section Il Paragvaphs 2.3 to 2.3.1 n, For engines Installed ina vertical stage, install all protective closures except for fuel overhoard drain line exit, Install suitable drainage line on fuel overboard drain line exit so that leakage flows externally from engine, o. Lock engine to s.vage attachment gimbal Do not lack actuators in positions that will cause LOX pump elevation to be below fuel pump elevation by more than 7 degrees. p. Place stage in an environmentally control- led avea meeting criteria specified in paragraph 2.0.1, 2,3 ENVIRONMENTAL REQUIREMENTS, i :NGINE hy NVIRONME: ben CONDI-. a3 i L engine. exposure ‘to rain, seta: dust, ete. “The ambient temperature of the engine environment must he within -20° to +140° Fata relative humidity of less than 95 percent except when the engine is stored inthe environment specified by Standard S-IC Stage Storage Specification MSFC- STD-500. During engine handling, with the engine installed in authorized handling equipment, the engine must not be exposed to acceleration loads exceeding 4g in any direc- tion, All parts of the engine that require protective closures or covers must be protected at all times unless otherwise indicated by the applicable procedures or requirements In this manual or by Standard 8-IC Stage Storage Specification MSFC-STD-500, 2-10B Change No. 14 - 9 October 1672 R-3806-11 a. Install suitable protective closures and/or covers on components ard assemblies smme- diately after removal fre m engine, b. Install suitable protective closures and/or covers on joints of engine where a component or asseinbly is removed, tmmediately after removal, ¢e, Transport components or assemblies requiring rework or inspection to an environ-~- mentally controlled area before removing pro- tective closures and/or covers, ad, Do not remove protective closures and/or covers fram components, assemblics, or engine joints until {mmedilately prior to .astallation of components and assemblies on engine, e. Inspect humidity Indicators of engines in storage and standby status in accos nce with section I requirements within a miaumum of one-calendar~month intervals and as follows: (1) Engines stored in accordance with Standard S-IC Stage Storage Specification MSFC-STD-500: If the 40-percent storage enviroument ia exceeded, thc humidity indi- cators must he inspected follow:ng correction of the environmental conditioning preblem, 910 950 (2) Engines in standby status: I'he humidity indicators must be inspected following exposure of the engine to an environment outside limits specified in paragraph 2.3.1. f, (Deleted) L Ql R-3690- 11 g Closures (hat require desiceant are as follows: Elosure Use Units Requires “af LOX inlet (a) 16 {each inlet)“ 48 Fuel inlet Thrust chamber throat h. Replace desiccant each time desiccated closures are removed for more than 5 minutes unless desiccant or closure with installed desic- cant i3 immediately placed in a desireant stor- age container as outlined in parayraph 2.3.6. } 2.3.2 NOZZLE EX''ENSION N ENVIRONMENTAL CONDITIONS, The nozzle extension must be stored horizontally or vertically on approved handling equipment or pallets and covered to prevent exposure to rain, sand, dust, ete. 228.8 EYRCTECHNIC 1GNITER ENUINONS: MENTAT Se eee ee arrears tet anenmeirrerse Tanwitieline and (2) earliest dale of fatneval from vontainer, 2,3.3,1 pectechnte Igniter & Storaee. The Does area for pyro otechnic igniters must be alccluis 2 specifically designed, located, and adipieled for storege of ordnance. If pyro- technic igniters containing one micracurie of radium are stored in excess of 100 units (either live ox spent), the storage area should dieplay a radiition identification and should be separate from nonradiating igniters, A maxt- mum of 1,500 units (live or spent) is recom- mended for storuge without special shielding and packaging, The handling and storage of live and spent ipniters that contain radiation material should be cooruinated with the radia- tion safety officer at the using activity. Stor- age area traffic must be kept to a minimum, a high level of housekeeping must be maintained, and the general safety practices must be con- sistent with the best practices for explosive storage arcas. Every effort must be made to maintain the storage area environment as con-~ stant as possible, keeping the relative humidity as low as poss ‘ible and the temperature between 0° and 120° F, (a) Only 12 units ave required when using closures having single seals on the desiccant cover. Section [1 Paragraphs 2.3.2 to 2.3.3.2 2.3.3.2 Pyrotechnic Igmter Service Life. Tie pyrotechnic igniter must he stored In its original Shipping contatner (can) tr an approved storage area until ready for use, Service life of @ pyro- technic igniter 4s as follows: a. Twenty-four months maximum from date of manufacture when packaged and stored jn its original containe:. NOTE The expiration date noted on the pyro- technic igniter container is deter- mined by adding 24 months to the date of manufacture, @ The "Install Igniter Before" date applies only to igniters that are in- Stalled in a ready-to-fire state for periods up to 6 mouths. b. The shipping container must be tagged or labeled with the date the pyrotechnic igniter was first removed from the container. The "Date First Removed" tag or label provides informa- tion for establishing the issuc/usage require- ments, c. A pyrotechnic igniter removed from its shipping container and not installed on an engine must be repackaged as outlined in paragraph 2.3.3.9. CAUTION The out-of-container uninstalled period must be held to a minimum to provide maximum: protection from handing and environmental damage. d. A pyrotechnic igniter removed from an en- gine due to cancellation of static test or launch is acceptable for reuse providing: (1) The shipping container is labeled with date of removal from engine. (2) The protective closure cap and shorting cap are installed imm ilately. (3) The igniter is not visually damaged, (4) The igniter gasket is discarded and re- placed with a new gasket. Section I Paragraphs 2.3.3.3 to 2.3.4.2 (5) The igniler is repackaged as outlined in paragraph 2.3.3,3. (6) The repackaged igniter is returned to an approved storaye ara, 2.3.3.3 Pyrotechnic Igniter Repackaging, It is recommended that pyrotechnic fgniters re- main in th: manufacturer's shipping container, undisturbed, until just prior to instalation on the engine or other mandatory functions that require its removal, This will assure maximum packaging integrity and a minimuia hanwling damage. During repackaging, the original shipping container must be used in order to re- tain Information concerning dates, classifica- tion, ete. During instatlation of new desiccant, the elipsed time hetyreen removal of the desic- cant from its container ana installation in the igniter container must be held to a minimum, Repackage igniters as follows: a. Make sure protective and/or shorting caps are installed. Install shorting cap when harness is cisconnected from igniter, b. Observe all safety precautions applicable at using organization, and wear recommended protective clothing. ¢, Inspect original shipping container (can) and polyurethane foam wrap, If moisture is visually evident, dry container and replace polyurethane form with dry polyurethane foam, a dd. Install 1/6 unit of new desiccant 934 RBO295-001 Kocketdyne) in bottom of can, é, Wrap igniter in polyurethane foam and place in can. f. Install humidity isulicator in can. g. Secure lid or vaporproof barrier material (MIL- B- 131) (0.002 inch thick minimum) to can with pressure-sensitive tape (Federal Specifica~ tion PPP-T-60), Tape must extend over can end, and ends of tape must be secured by apply- ing a layer of tape around periphery of can end. NOTE Vaporproof barrier material (MIL- B-131) may be replaced by a barrier material with equivalent moisture vapor transmission properties. 2-412 Change No. 13 - 4 April 1972 R-3896-11 2.3.3.4 Pyrotechnic Igniter Disposal. Snent or used igniters should be collected and held for disposal in accordance with the instructions of the radiation safety officer of the using activity. Spent igniters should be treated as radioactive material in accardance with applicable Atomic Energy Commission regulations or in agreement witn state regulations, Tle maximum number of igniters to be held fox disposal is 1, 500 (con- tains approximately 1,5 millicuries of radium). 2,3.4 NYPERGOL CARTRIDGE ENVIRON- MENTAL CONDITIONS. The order of usage for the hypergol cartridge is (1) earliest date of manufacture and (2) carliest date of removal from container, 2.3.4.1 Hypergol Cartridge Storage, The stor- age avea for hypergolic cartridges must be a structure specifically designed, located, and designated for storage of ordnance. Storage area traffic must be kept to a minimum, a high level of housekeeping must be maintained, and the general safety practices must be consistent with the best prac.ices for flammable«liquid storage areas, Every effort must be made to maintain the storage area environment as con- stant ao possible, keeping the relative humidity as low as possible and the temperature between 0° and 120° F. shipping container (can) in an approved flam- mable-Hquids storage area until ready for use. Service life periods specified pertain to a hyper- gol cartridge that has no’ been mishandled or internally damaged ina manner that would not be readily visible, Service life is as follows: a. Twenty-four mouths maximum from load- ing date when properly packaged and stored, NOTE The expiration date noted on the hy- pergol cartridge is determined by adding 24 months to the loading date. b. The shipping container must be taped or labeled with date hypergol cartridge was first removed from container. The “Date First Re- moved" tag or label provides information for eslablishing the issue/usage requirements. bA. Ii the polyethylene bag (both bags if duuble packaged) is noted to be torn after removing the nypergol cartridge from the shipping container, the hypergol cartridge must be restored for service as outlined in paragraph 2,3.4,2A. ofe ury 910 A 2.3.4.3 Hypergol Cartridge Pepackaging. A hypergol varlridgée should remain installed in g the manufacturer’ s g turbed until just prior to installation in the en- g requiring its removal, & mum packaging integrily and minimum handling A damage. A hypergol cartridge is repackaged a when the following requirements are met: R-3896~i1 c. A hypergol cartridge removed from its shipping container must be immediately in- stalled in an engine or repackaged as outlived in paragraph 2.3.4.3, CAUTION The out-of-container/uninstalled period must be held to a minimum to provide maximum proteclion Crom handing und environmental damage, dad. An unexpended hypergol cartridge re- moved from an engine due to cancellation of static test or launch is acceptable for reuse providing: (1) The hypergol cartridge is repackayed as outlined in paragraph 2.3.4.3, (2) The hypergol cartridpe is not damaged durjng removal from engine or during repack- aping. (3) The shipping container is labeled with date of removal from engine and the container returned tu an approved Flammable-liquids storige aren, 2,3,4,2A Hypergol Cartriuge Restoration, A hypergol cartridge will he returned to a sé vice- able condition when the following requirements are met; a. The existing packings and ring are re- moved from the hypergol cartridge. b. The hypergol cartridge is thoroughly cleaned of all contaminants, ec. The hypergol cartridge is visually in- spected and found to be free of contaminants and/or damage. d. New packinus are lubricated and packings and ring are installed on the hypergol cartridge, The shipping conlainer undi3- gine, or any any other mandatory procedure This will assure maxi-~ a. The lL vergol cartridge is visually in- % spected and found to be froe of contaminants B and/or damage. b, The hypergol cartridge shipping container g and cushions are inspected and found to be free f of 1noistuse. Seetion iI Paragraphs 2.3,4,2A to 2.3.6.4 ec. The hypergol cartridge is double packaged in individually sealed polyethy!ene bags before wrapping the des cartridge in a cushion. The hypergol cartridge {s wrapped in the cushion before inserting the hyperpnl cartridge into the shipping container with cushions positioned at each end of the hypergol cartridge, 912 dad. The hypergol cartridge is vepackaged in the original shipping container with the original in- ease (concerning dates, classificafion, etc) retained. e. Covers and gaskets are installed on each end of the shipping container and secured with locking rings. 2.3.4.4 iypergol Cartridge Disposal, Spent or over-aged hyper ol cartridges must he returned to Rocketdyne. 2.3.8 MISCHLLANIOUS LOOSE EQUIPMENT ENVIRONMENTAL, CONDITIONS.” MisccTiancous loose equipinent is defined as those items of engine equipment shipped with the engine and required for engine installation in the stage, Accountability of the equipment must be main- i tained and the equipment must be properly pack~ aged, Storage environment must be within the 930 limits required for engine storage as cutlined [ in paragraph 2.3.2, 2.3.6 DESICCANT ENVIRONMENTAL CONDI- TIONS, Vhe F-1 engine closures require a desiccant 2130295-001 (Rocketdyne) packaged ir 93% dust-free, high-burst-and-tear-strength plastic bags. Desiccant used in engine closures musl 95h not be reactivated, Packaged desiccant may he a obtained in various unit sizes ranging from fractional units of 1/16, 1/3, and 1/2 to sizes of 1, 2, 4, 8, and 16 units and may be utilized in any combination, 2.3.6.1 Desiccant Storage. Desiecant must be stored in’a sealed metal container (20+ or 30+ nullon size) having an airtight, gravity, self- ocking door and an externally mounted humidity indicator with a three-spol indicating element for 20, 30, and 40 percent relative hutnidity ranges, A caution must be stenciled directly on the exterior of the container staling: "This container contains moisture-aksorbent desiccant, Do not open container except to remove desic~ cant. Reseal immediately, Take only the quantity required for immediaic use." If more than one size of desiccant is stored in a con- lainey, segrerate units by packaging each size in separate plastic bage, The plastic bags may be closed in any manner that will provide ready access to the desiccant and that will eliminate the possibility of physical damago to desiccant bags. The rclative huraidity in the storage con- tainer must be maintained at less than 20 per- cent relative humidity. If the 20-percent spot on the storage container turns a color other Change No, 14 - 9 Octoher 1972 a-13 Section ih Paragraphs 2.3.6.2 to 2.4, 3A than blue, the entire contents of the storage container must be replaced with a new supply of desiccant. Desiccant removed from the storage container and not installed and sealed ina closure within a maximum of 5 minutes, may be stored outsiae the container for a maxi-~ mum of one hour ff the desiccant is placed In a polyethylene bag (6-mil ininimum thickness), Excess air must be squeezed from the bag and the open end of the bag must he folded, closed, and sealed with tape before the 5 minutes lapses, ee ee Re et eee pry The time phase between removal of desiccant from stor- age until sealing Ina protective closure must not exceel 5 minutes, or desiccant must be M4discarded, Desiccant bags must always he 910 handied ina manner that will prevent tearing or rupturing of the bags. Immediately prior to installing desiccant in a closure, the desic- cant bag must be wiped with a clean, hemmed, nylon cloth moistened with cleaning compound (MIT.-C-81302), The quantity of desiccant used in a particular closure is as stated on the clo- sure or as specified in this manual. Specific requirements for desiccant in relation to the engine are as follows: WARNING Cleaning cunipound (MIL. C-81302} {s volatile, Use in a well-ventilated area since the vapors displace the omypen in tho air, resulting in suffocation, a, After engine receipt or during a raceiving inspection, replace desiccant if 40-perecew rela- tive hurnidity indicator shows color ather than blue, hb. During engine slorase, make sure fucl closure, oxidizer closure, and thrust chamber security closure 30-percent relative humidity indicators show blue color. If color other than blue is noted, change closure desiccant. c. When desiccant is replaced, inspect humidity indicalor after 24 hours. Jf 30-per- cent relative humidity range shows color other chan b)ue, replace desiccant and repeat inspection after 24 hours. dad. Sf relative- humidity indicator colors overrun their borders duc to excessive moisture, replace indicator. ax 14 Change No. 13 ~ 4 April 1972 R~3896-11 e. When desiccated protective closures are removed from engine, compare number of bags and units with number recorded and account for all desiccant before processing hardware. Note condition of bags. If hardware contamination is suspected as result of discrepant bags, verify condition of processing hardware, 2.4 MAINTENANCE REQUIREMENTS, 2.4.1 SEAL USAGE Seals from connections that have been disassembled must be repliced with like-serviceable items whenever a visual inspection reveals contaminants, nicks, scratches, or any other defect that may impair sealing capability, A new K-seal must be in- stalled whenever a K-seal joint, except for seal monitoring “ort plugs, is loosened o¢ opened. Pressure- ‘uated (Naflex) seals, except for the seal usea at the oxidizer overboard drain line flange (at thrust chamber to sozzle extension joint during statie test at MTF), must be ve- placed and returned to the Engine Contractor for disposition svhenever a joint is loosened or opened, 2,4.2 FASTENER USAGE. Bolts removed from the engine or compynents must be replaced whenever a visual inspection reveals damare to the bolthead, grip, theeads, plating, or dry- film lubricant. Undamaged bolts may be reused unless otherwise specified. Nuts may be reused if threads and wrench flats are not damaged. Self-locking mits may be reused if the locking feature still provides positive torque drag. Washers ace reusable as long as the plating is noi dam:ged and the surfaces are not deformed. Any ertine fastener disturbed during p2rform- ance of authorized activities must be retorqued te its applicable torque value at ihe completion of that activity. 2.4.3 FASTENER CROSS- TORQUE HIs- QUIREMINY, The cross-torquins method must be vsed tor multifastener opplication of flanges or joints, to apply evenly daisiributed axial loads ty seals and gaskels. Torque oust be applied in increments of one third of the total torque to be epplied until all tasteners are evenly iorqued iv the desired fargue value. 2.4.34. DAMAGE DISPOSITION, All damage to the engine, regardless of magnitude or nature of disercpancy, must be considered as either one of the following conditions: a, Acceptable without repair if within the acceptable damage limits specified in figure 1-3, 97112 R-3896-11 Section li Paragraph 2.4.4 b. Not acceptable without repair or further 2.4.4 COMPONENT REMOVAL, INSTALLA- evaluation to determine an appropriate disposi- TION, REPAIR, MONTY ICATION, ANT IN-~ tion, This type of uamape is identified by the SPE CTTION CONSTRANINS. Component re= entry "No damage allowable" to the Limits moval, replacement, and reinstallation must be colunin of figure 1-3. Generally, this apphes accomplished using authorized and approved to damage for which no acceptable damage procedures and equipment, Field modifications Iiniits haye been formulated. Each damage of approved WCP's and inspections by FFIR's occurrence must be evaluated on an individual may be accomplished at any field location, See basis in accurdance with the authorized sile figures 2-6 for detail requirements on compo- cis crepancy repurting system. nent replacement, reinstallation, and adjust- meni, cy When Com- ponent Is When Com- ponent Is Adjusted, Adjusted, When Com- Disturbed, When Com~ Disturbed, Compenent ponent is ox Component ponent is or Nomenclature Rephiced Reinstatled Nomenclature Roplaced Reinstalled Thrust chamber hody — (a) (b) (ce) {c) No. lor No. 2 fuel {ts) (b>) pump inlet duct Thrust chamber (a) {b) (e) {a) fb) (a) injector Adjustment of brackets - pat rT ya and associated nes: rust chamber dome (2) (b) (ec) (ct) (a) (Ce) (d) Heat exchanger (es (e) Turbopump (b) (ce) (b) (e) helium outlet LOX pump inlet (Id) (b) Heat exchanger (e) (e) Heat exchanger (e) (e) nese ere ne er ee) ea GOX = (e) (ce) LOX orifice plate No. lor No. 2 main ({c) Hydraulic ground (ec) (e) fucl orifice plate supply Interface panel {b) {b) Hydraulic ground {e) (e) return Gimbal (a) (a) High-pressure ducts (c) (c) (a) Adjust gimbal Xq and 2. axes using? Gimbal Bearing Locks G4059, holding fixture T- 6037454, and check reruns J -5037452 so thal dimensions from gimbal center to outer diameter surface of 4 thrust chamber injector alinement pis are within 0,010 inch. Record new gimbal settings in Engine Log Book. Verify that interface location dimensions are within limits specified in F-1 Engine Interface Pocument R- 6749, (c) Reaffirm that propetlant duct fit check and alinement are within limits of figure 2-7. (d) A torque check of the outer dome bolts is required at coinpletion of second firing (first if uy one 1s performed). Using appl cable holding fixture T- 5037454; alinement tools ‘T- 5039113, T-6041233, and T- 5040948; and Gimbal Bearing Locks G4049, adjust bracketry and/or associated lines to correct ioeations. ed (b — {e a AR Eo ERIN AA NE Aca A A NET re A SS Figure 2-8, Component Replacement, Reinstallation, and Adjustment Requirements (Sheet 1 of 2) Section i R-3B96- 11 ee A A ERNE 8 OT RRR YN ase OY ST AP BO Ae te RL LE ER eR A MS a ba When Com- ponent Is When GCoim- ponent Is one (ge) Or Orifice size must be the same as that specified in the ls ngine Log Book. Adjusted Adjusted, When Com- Disturbed, When Cuin- Disturbed, Component ponent is an Component ponent is or Nomeaciature Replaced — Reinstalled Nomenclature Replaced Reistatted High-pressure (c) {c) Cocoun conditioning (f) () duct spacers purge line No. l and/or No, 2 (c} (c) LOX dome and gas (f} (f} oxidizer valves penerator LOX injector purge Hine No, 1 amil/or No. 2 (c) (c) tuel valves Lax pump seal (f) {1} purge ling Uydraulic control (f) (C) Bearing coolant (2) (x) ene swete ; ‘ system lines control valve (c) Reaflirm that propeltant duct fit check and alinement are within limits of figure 2-7, {f) Reaffirra that line alinemnent 15 within limits of figure 2-8. te a rt neni Ha Figure 2-6, Cornponent Replacement, Reinstallation, and Adiustrent Requirements (Sheet 2 of 2) en ern a Spt NN ERY AR Ler lO mY he NN hs hte Maximum Axial Gap Maximum at Largest Space Differential Joint Location (Inches) Gap(a) (Inches) No. 1 oxidizer duct to turbopump volute 0.040 0.020 No. | oxidizer duct to valve 0. 049 0.020 No. 2 oxidizer duct lo turbopump volute 0.040 0,020 No. @ oxidizer duct to valye 0 040 0.020 No. 1 tucl duct to turbopymp volute 0,040 0.020 Wo. 1 fuel duct to valve 0. 180 (0,190 for 0,020 horizontal assembly) No. 2 fuel duct to turbopump volute 0.040 0,020 No. 2 fuel duct to valve 0.060 (0.040 for 0.020 horizontal assembly (a) Phe * "Reaximum Differential Gap" is the difference between the pap obtained at the largest space and the gap obtained at the smallest space, Figure 2-7. te rrr i a ate re Propellant Duct Fit-Check and Alinement Requir ements ss (Sheet 1 of 1 of 2) 2-16 Change No. 6- 10 February 1970 R-3896-13 Section I ~ Maximum Axial Gap Maximum at Largest Space Prete bi pee _ ; Joint Location _ _ilnches) Sap a, ilnches) | No, 1 oxidizer valve to LOX dome inte) 0. 065 0.015 Yo, 2 oxidizer valve to LOX dome intet 0.065 0.015 No. 1 fuel vaive ta fucl manifold inlet (b) 0.065 0.015 No, 2 fuel valve to fuel manifold intet”) 0.065 0.016 (a) ‘Fhe ‘Maximum Putferentiai Gap" is the difference between the gap obtained at the largest space and the pap obtained at the smallest space. (b) These allowable eap dimensions are applicable only for the following fit-check cases: (1) Removal and reinstallation or replacement of the LOX dome and injector with the oxidizer ducts remaining attached to the turbopump and the oxidizer valves. (2) Disconnection of fuel valves from fuel manifold with fuel ducts remaining attached to the fuel valves and turbopump. Fipure 2-7. Propellant Duct Fit-Check and Alinement Requirements (Sheet 2 of 2) Maximum Allowable Limits “Offset Gap Angulation(a i} Jolut Location (Inch) (Inch) (Inch) : Line No. 1 fucl valve open control No. 1 fuel valve 0.30 30.30 0.017 tuhe Propellant valves close tube No, 1 fuet valve 9, 02 $0.10 0.009 No, 2 fuel valve open control No. 2 fuel valve 0.05 10.20 0.017 tube Propellant valves close tube No. 2 fuel valve 0.10 +0. 20 0.017 No. 1 oxidizer valve dome No. 1 oxidizer dome purge 0.10 +0.05 0. 009 purge linc check valve Sequence valve to sequence No. 1 oxidizer valve sequence 0.15 +0, 30 0,017 valve line valve Propellant valves open tube No. 1 oxidizer valve 0.05 #0.15 0,011 No. 2 oxidizer valve dome No. 2 oxidizer dome purge 0.10 410,05 0.069 purge line check valve Propellant valves open tube No. 2 oxidizer valve sequence 0.10 +0. 15 0.017 valve a) Angulation is determined after Ine is alined within offset and gap requirements. Se a sy Figure 2-8. Tube Alinement Requirements ‘Sheet 1 of 2) Change No, 9 - 2 December 1970 2-17 eee Section Il Paraprvaph 2,4,4A A tube 2.4.44 COMPONENT REPLACEMENT ereucts OM ENGINE PERFORMANCE AT SEA LEVEL. Component t replacement effects on n engine performance at sea level are tabtu- lated in figure 2-9. The deviations presented are the maximum expected effects an sea-level engine thrust and mixture ratio when tne listed components are replaced. The following pro- cedure is to he used for determining the maxi- Inum expected performance deviations for indi- vidual engines: a. The deviations listed in figure 2-9, cor- reuponding to hardware replaced on the engine, are to he tabulated and included with the Engine 2-18 Change No. 9 - 2 December 1970 R-3896-11 Maximum Allowable Limits Ofiset Gap Angulation!@) Line Joint Location (Inch) (inch) (Inch) @ Propellant valves open tube No. 2 oxidizer valve 0.07 20.15 0.011 f Propellant valves open tube Ignition monitor valve inlet 0.05 40,02 0,012 & Ignition monitor valve sense Thrust chamber fuel manifold 0.03 +0, 10 0,014 pf tube 8 Propellant valves close tube Na. 2 oxidizer valve 0.15 +0, 20 0. 024 : feniter fuel supply tube No, 1 fuel high-pressure 0,10 +0, 160 0,022 duct or hypergol manifold +0.001 7 Engine supply tube No. 2 fuel high-pressure duct 0,05 +0, 100 0, 020 or engine control valve +0, 001 e Gas generator system close Gas generator 0.10 40.20 0.017 f tube : Gas renerator system open Gas generator 0. t0 +0, 40 0.054 ! (a) Angulation is determined after line is alined within offset and gap requirements. Figure 2-8. Tube Alinement Requirements (Sheet 2 of 2) Log Book. This tabulation is necessary for future reference and continuous updating when additional replacements are made. L. The combination of deviations due to the replacement of each individual component determines the expected maximum performance deviation. The combination is accomplished vy enieulating the square root of the sum of the squares of the deviations listed in figure 2-9, corresponding to cach component replaced. Components replaced a second time are treated as a single replacement of the item. (No addi- tional varistion is added besides the variation for the component being reple.ced a secondtime.) 1%-3898-11 Section FE tate Ata warm at arntn ant i Reese ie © RE Maximum Expected Performonce Uncertainty Reason For Seas Level Thrust | Sea- Level Component Being Replaced Test {K ih) Mixture Ratio Fuel pump (a) {b) 26.9 0,044 No. 1 inlet elbow 9.0 0,014 No. 2 inlet elbow 9.0 0.014 Inlet assembly (a) (b) 9.0 (0,014 Inducer (a) (b) 9.0 (.014 Volute (n) (bh) 18.9 0.029 impeller (a) (b) 13.0 0,019 Turbine assembly (i) (b) 35,6 0,005 Nozzle (manifold) fa) (b) 19.1 0,001 First-stage wheel {a} (b) 17.6 0. 002 Per blade {a) 0, 2 0,4 Second- stage wheel ia) (b) 8.8 0.001 ey blade (a) 0.4 0.0 Stator (a) 17.6 0. 002 Per segment (a) 1.8 0.0 Honeycomb seal (a) 17.6 0.002 Gas generator oxidizer bootstrap line secop 6.0 0,001 Gas generator oxidiszcr bootstrap tine 12.0 0. 002 (upstream) Gas generator oxidizer upstream orifice (a) 1.9 0.0 Gas generator oxidizer bootstrap line 12.0 0. 002 (downstream) Le settalunmcmmatentatoamtekainenameet {a) Replacement of this component requires reorificing and/or retest for performance uncertainty and redline valve acceptability as mutually agreed by Engine Contractor and NASA. (b) Component hot-fibre vest required for functional integrity verification A ll A EE Figure 2-9, Deviations in Engine Performance Due to Component Replacement (Shect 1 of 3) Change No, il - 6 May 1971 2-18A/2 -18)3 R~3396-11 Section FI oanan ma Maximum Expected Performance Uncertainty Sea~ Level Thrust Sea- Level (K Ib) Mixture Ratio Sean ceed aetna Reason For Test Component Being Replaced Gas generator oxidizer downstream (1a) 1.9 0.0 921 orifice Gas generator fuel boutstrap line 7,8 0. 004 Gas generator fuel orifice (a) Let 0.0 Cas generator ball valve 21.2 0. 004 Gas generator injector (a} 31.6 0. 005 Gas generator combustor body 11.7 0.001 Thrust chamber (a) 21.5 0, 054 Thrust chamber {a} (e) 11.5 0,043 Main injector {a) 6.5 0. 029 Oxidizer dome 17.0 0.016 Turbine exhaust system duct with heat 27.0 0.003 e: changer Nozzle cxlension 15.0 0.0 No. 1 main LOX orifiee (a) 0.1 0.0 No. 2 main LOX orifice (a) 0.1 0.0 No. 1 main fuel orifice (a) 0.0 0.0 No. 4 main fuel orifice ; fa) 0.1 0.0 Ne 1 main oxidizer valve 13.0 No. 2 main oxidizer valve 20.1 0. 912 No. i saain fuel valve 1,1 9.6 No. 2 iain fuel valve , 0.018 No. 1 turbopump oxidizer outlet line 1.3 0.002 No. 2 lurbupuinp oaidizer outlet line 4,1 0. 003 Nu. 1 turbopump fuel outlet line 0.2 0.003 No. 2 turbopump fuel outlet line 1.4 0. 003 (a) Replacement of this component requires reorificing and/or retest for performance uncertainty and redline value accaptahility as mutually agreed by Eagine Contractor and NASA. (c) Single engine hot-fire test required for functional integrity versficalion el Lememehaetheadeheimendene tien than “aheananpaedttiaiaaaieee and Figure 2-9, Deviations in Engine Performance Cue to Component Replacement (Sheet 2 of 3) Change No. 11 - 6 May 1971 a~19 Section H R-3896-11 Paragraphs 2.4.5 to 2,4.8 re eee caress AS LI MECN EE CNN Maximum Expected Performance Uncertainty Reason ~ eRe ae For Sea- Level Thrust Sea- Lovel Component Being Replaced Test ({K lb) Mixture Ratio Turbopump (a) 55.0 0.071 Oxidizer pump (a) (b) 30,2 0.055 Talat assembly 7.3 0. 014 Inducer (a) 7.3 0.014 Volute fa) (b) 15,8 0.028 impeller (a) (b) 24. 6 0. 043 (a) Replacement of this compunent requires reovificing and/or retest for performance uncertainty and redline value acceptatulity as mutually agreed by Engine Contractor and NASA. (b) Component hot-fire test required for functional integrity verification NOTE Component hot-fire test is required after removal and reinstallation or replacement of turbopump internal components from the No. 3 fuel seal to the first-stage turbine wheel. eet Ratt A A Figure 2-9. Deviations in Engine Performance Due to Component Replaceinent (Sheet 3 of 3) ra etre a 2.4.8 ENGINE ORIFICE VERIFICATION. In 2.4.5 LOCKWIRE REPLACEMENT. Lockwire ET a aoe mw, removed to pccomplish authorized activities must be replaced at the completion of those activities, 24.4.6 COVER AND CLOSURE REQUIREME All parts of of the engine requiring tee eovers or closures must be protected at all times unless covers are required to be off for performance of an authorized activity. 4.4.7 ENGINE SOFT GOODS VERIFICATION. An age control lug fur components that contain soft goods is pravided in each Engine log Book If it becomes necessary to replace a component that contains soft woods, the Engine Log Bonk age control lo nust be updated to reflect the new replacement date. Ti+ replacement date ig the installation date of the soft coods in the glacumponent plus 32 quarters. 2-20 Change No. 7 - 28 April 1970 a of conflict between oritice diameters, as ecorded in the Engine Log Book, and the exter- wal identification of an orifice, the orifice must be removed from the engine and the ori‘ice diamete: imeasured. If the actual orifice diatn- eter differs from that recorded in the Engine Log Book, notify Engine Contractor for disposi- tion. NOPE Yhe actual orifice diameter and the orifice diameter recorded in the ingine Log Book may differ by the allowable machining tclerance of the individual orifice. R-3896-11 2.4.9 CLEANLINESS REQUIREMENT FOR EX’ EXTERNAL ¢ CONNECTIONS. All components and lines that transfer fluids to engine systems must meet cleanlincs. requirements of engine system hardware prior to connection to the en- gine system, 2.4.10 SYSTEM INTERCONNECTION CON- STRAINTS, Systems thai transfer fluids (o the engine ine must be plumbed, unless otherwise specified, so that fluids cannor intermix, 2.4.11 TURBOPUMP PRESERVATION RE- QUIREMENTS. ‘Preservation of the turbopump is required at ‘the following times: a, Within 4 hours after: ( 1) An engine test that introduced fuel into 924 the turhooump lubrication system. (2) A launch abort, (3) Lubrication system purge in excess of 50 psig. 937 b. Every 10 years. c, lf a preserved turbopump is exposed to fuel while horizontal, the engine shall be rotated to vertical within 6 months of the event and fre turbopump bearings represerved within an addi- tional 4 months, 2.4.12 HARDWARE ATTACHMENT CON- STRAINTS. . Engine ¢ Contractor Design Review and concurrence of applicable Stage Contractar installation documents must be obtained before attaching any additional lines, harnesses, brackets, clairps, or other hardware to the engine, Attaching hardware to the engine in locations other than those agreed upon during Design Review by the Engine Contractor may result in reduced engine reliability, Unless gno otherwise specified, constrainis for installation of attaching hardware and rainimurn clearance between attaching bardware and engine compo- nents are as follows: a. Minimum clearance between atlachitg hardware and eupine lines: {1} Static conditions: A minimum clearance of 1/8 inch must be maintained between rigid lines and adjacent surfaces. (2) Dynamic conditions (independent of vibration): A minimum clearance of 1/2 inch Section IL Paragraphs 2.4,9 to 2.4.12 must be maintained between the maximum clear- f ance envelope of rigid lines and adjacent sur- : facos . (3) A minimum clearance of 1/2 inch must be maintained between flexible lincs and adjacent § surfaces, : b. Rigid line support requirements: (t) Lines 1,4 inch through 3/8 inch in dia- meter must be supported every 18 inches (maximum). , (2) Iuines 1/2 inch through 3/4 inch in diameter must be supported every 25-1/2 inches § (maximu:n). (3) Lines one inch and over must be sup- ported every 30 inches (maximun)). (4) One-third of distance specified in sub- steps { through 3 is maximum spacing between unsupported line fittings or to bends of more than 75 degrees. 902 c. Attaching hardware must not be clamped =. to line flexible sections. d. Clamping between attaching hardware and § engine lines must not stress engine lines. Under] no circumstances shall any hardware be attached § to engine hydraulie control lines. «. Components must not be mounted on engine § lines. FE f. Clearance of 1/2 inch minimum must be maintained betwecx attaching conventional elec- trical harnesses and any line carrying a flam- mable fluid, including liquid oxygen. g. Clearances inust be maintained as speci- § fied in step a between attaching flexible arrnored | harnesses and éngine lines. h, Attaching flexible armored harness must not be in direct contact with any component that contains or flows hot-gas products, other than the norma} connecting of a harness plug toa camponent. Contact by a support attached toa hot-gas component is acceptable. Change No. \4 - 9 Octoher 1972 2-21 Section I Paragraphs 2.5 to 2.5.2 2.5 OPERATIONAL TEST REQUIREMENTS. 2.5.1 SAFETY REQUIREMENTS WHEN WORK- ING WITH THERMAL INSULATION. a. Wear leather gloves and arm protection to prevent injury from sharp edges and corners of insulators. b. Do not force-fit brackets. c. -Use enougn personnel when handling insu- lators to prevent buckling or distortion of panels. CAUTION Because of the extreme lightness of insulators in comparison with their surface area, they must not be placed where winds or drafts could blow them about. d. Use extreme care when handling insulators in windy areas. e, Leave protective packaging on insulators until ready for installation. f, Do not stack or pile Insulators on work platform. g. Use tieduwns to secure insulators; do not use weights. h. Protect insulators froin punctures or tears when handling near sharp projections or toals. i. Do not place equipment against insulators or use them for hand or fvot holds, j. Do not bend flange tabs of insulators to a sharp radius. k. Do net expose insulators to liquids or moisture. The insulation between foil sheets cannot be conveniently dried. Insulation dam- aged by fuel absorption must be replaced prior to engine firing, 1 Make gure that vent covers on Inner folls of cocoon and thrust chamber and nozzle extene sion insulators are not distorted and are free of obstructions. 2-22 Change No. 6 - 10 February 1970 R-3896-11 m. Insulators must not be alined with drift pins engaging nut plates of brackets. n. Do not wear clothing containing sharp ob- jects that may damage engine finishes, o. Exercise extreme care to prevent damage to engine equipment. p. Insulators are not rigid components until installed. If misalinement of attaching features occurs due to deformation of insulators frora handling, it may be necessary to use hand-force to effect installation. To prevent darnage to in- sulators, apply hand-force tu large areas either by pushing or striking with the heel of the hand. Wear gloves to prevent injury toe hands. 2.5.2 SAFETY SHIELDING AND SAFE OPER- ATING TE TEST PRESSURES, F-T engine system safe operating test pressures for personnel safety are as listed in figure 2-10, Safety shield- ing must be used on engine/components during performance of authorized activities in this manual that specify pressures in excess of the values listed. R- 3896-11 2.5.3 SAFETY REQUIREMENTS WHEN WORK- ING WITH PNEUMATIC AND ii HYDRAULIC S¥s- TEMS. a. Prior to pressurization of any system, verify that all connections on the system are fully engaged, and safety precautions, «uch as warning signs and warning lights, are displayed. b. Do not tighten or loosen any fitting on a pressurized aystein. c. Do not leave pressurization controls un- attended when pressure is applied to a system. d. Verify that test equipment hoses or lines are depressurized prior to disconnection, e. Secure all test hoses connected between test equipment or facility and/or engine, to prevent whipping in event of accidental dis- connection or line failure, f. Wear safety glasses or face shield when working in areas where systems are pres- surized, g. If any fitting or Une is loosened or any part removed, protect opening against entry of foreign material. h. Inthe event LOX propellant feed system is depressurized with fuel propellant feed sys- tem pressurized, make certain nitrogen over- board drain is not plugged, i. If closures are io remuin on overboard drain lines when LOX and fuel propellant feed systems are pressurized, closure fasteners must be loosened to prevent possible pressure buildup in drain lines. 2.5.4 SAFETY REQUIREMENTS WHEN WORK- ING WITH ELECTRICAL SYSTEMS, a. Deenergize circuits before working on electrical components or electrical cables. hb. Place circuit breakers controlling the power source and all switches on the electrical equipment in the off or deenergized position prior to connecting a power source to electrical equipment, c. Ro not leave electrical controls unattended when electrical power is supplied to an electri- cal systein, d. Ground engine and electrical consoles to & common ground with separate ground cables. Section It Paragraphs 2.5.3 to 2.5.5 4.8.5 SAFETY REQUIE LE MENTS WHEN WORK- ING WITH SOLVENTS. The hazard associated — with a solvent 1s specified in the requirement or procedure by a warning note since improper use of a solvent can cause injury to rersonnel or damage to equipment. The follos.ing steps list the solvents used, their particular hazard, and the yafety precautions that should be followed when using that solvent. a. Observe the following safety precautions when using trichloroethylene (MIL-T-27602), or equivalent: (1) Avoid excessive inhalation of vapors from trichloroethylene. Trichloroethylene gives off vapors even at room temperature, and pro- longed inhalation can produce noircotic effects on the nervous system. (2) Do not allow trichloroethylene to con- tact skin for prolonged periods since it can be absorbed through the askin. The liquid chemi- cally dries the skin, leaving it susceptible to infection, (3) Wear safety glasses or face shield while using trichloroethylene, (4) Wear a breathing apparatus while work- ing with trichloroethylene ir confined or unventi- lated areas. (5) Do not expose trichloroethylene to ex- cessive heat, b. Observe the following safety precautions when using cleaning compound (MIL-C- 61902), or equivalent: (1) Avoid excessive inhalation of vapors of cleaning compound as it may cause headaches, dizziness, sleepiness, or unconsciousness due to the oxygen-~deficient atmorphere. (2) Do not allow cleaning compound to con- tact skin for prolonged perioda. The liquid chemical dries the skin, leaving it susceptible to infection, (3) Wear safety glasses or face shield when using cleaning compound, Information will follow at a jiater date. Figure 2-10. Safo Operating Pressure Requirements Change No, 6 - 10 February 1970 2~23/2-24 R-3896-11 (4) Wear a breathing apparatus when using cleaning compound in confined or unventilated areas. (5) Do not subject cleaning compound to excessive temperatures, c. Observe the foltowing safety precautions when using isopropyl alcohol (Federal Specifi- cation TT-I-735), or equivalent: (1) Avoid excessive inhalation of vapors of isopropyl alcohol since prolonged inhalatioa may cause slight intoxication, (2) Wear breathing apparatus when using isopropyl alcohol in confined or unventilated areas, (3) Because of its low vaporizing qualities, use the least amount of isopropyl alcohol con- sistent with performing the task. (4) Wear safety glasses or face slield when using isopropyl alcohol, (5) Do not use isopropyl alcohol near source of ignition heat or open flame. d. Observe the followiny safety precautions when using drycleaning solvent (Federal Speci- fication P-D-680), or equivalent. (1) Bo not use drycleaning solvent near source of inition, heat, or open flame, (2) Woar safety glasses or face shield when using drycleaning solvent, 2.9,6 SAFETY REQUIREMENTS FOR THRUST CHAMBER ENTRY. “The minimum m safety rev quirements that must be followed when personnel enter the thrust chamber are as follows: a. ‘The man lift, if employed, must he cap- able of operation from the work platform or from ground level, b. Breathing apparatus must be worn when entering the thrust chamber, «. The buddy systern must be used when per- sonnel enter the thrust chamber. The standby personnel must be qualified in fachlity operation, operation of the breathing apparatus, and oper- ation of the lift equipment. The standby per- sonnel must always remain in line-of-sight of the person in the thrust chamber. Section II Paragraphs 2.5.6 to 2. 5, 8 d. Isolate thrust chamber assembly in such a manner that inadvertent pressurant or pro- pellant admission is impossible. e. Verify with an explosimeter that combusti- ble vapors in thrust chamber are less than 20 percent of lower explosive limit of combustibles prio to allowing personnel entry into thrust chamber to make spark-producing repairs. A list of combustible materials that might be used in the thrust chamber and their explosive limits is as follows: 20 Percent of Lower Limit (Per- cent by Vol- Lower Limit (Percent by Volume in Material Air) ume in Air) Alcohol (isopropy)) 2.9 0.4 Ethylene plycol 3.2 O.¢ Fuel (RJ-1 and 1.6 to 6 0.3 to 1.2 RP- 1) Freon (cleaning none none compound) Solvent (stoddard) 1,1 0.2 Trichloroethylene 12.0 2.4 2.5.7 SAFRTY REQUIREMENTS FOR HAN- aera errsey mere ot orate DLING IGNITERS RS AND ND HYPERGOL | CARTER RT RIDGE. Wear the following protective clothing: a. Fire-resistant body-length open-back asbestos smock with snap-on straps for rapid removal. Smock should hang about 6 inches from the floor. b. Heat-resistant gloves, fitted oversize so that they can be rapidly shaken from the hands. c, Face shield with a full-view plastic win- dow. Shield must cover from the crawn of the head to helow the chin including part of the neck. d. Knee-Jength neoprene bouts, 2.5.8 GROUND SUPPORT EQUIPMENT AND SPECIAL AL TOOL REQUIRE MENTS, The ground Support equipment and special tools used in con- junction with the authorized activities in this manual must meet their respective test and in- spection requirements prior to usage. 2-25 Section Il R-3896-11 Paragraphs 2.5.9 to 2,5, 10 2.5,9 ENGINE SERVICE LIFE. The total 2.5.10 COMPONENT ¢° OLE LIFE LIMITS. service life of the engine, in terms of operating Record component cycl.o due ing engine check- time and number of starts, is 2,250 seconds of outs for the listed components on data forms operation within 20 engine starts. An engine contained in the Engine Log Book. Contact start is defined as attainment of site thrust Rocketdyne representative for an engineering equal to 80 percent of rated thrust. recommendation as to hardware disposition 2.5.9.1 Component Service Life. A torque eae limits, as defined in figure 2-11, check of the oxidizer dome bolts is required at 1,350 seconds of engine firing. Name Cycle Definition Cycle Limit Fuel valve Anytime the valve leaves the closed 900 position, reaches the open position, and returns to the closed position, as indicated by the valve position switches, independent of the fluid or pressure used, Oxidizer valve Anytime the valve leaves the closed 900 position, reaches the open position, and returns to the closed position, as indicated by the valve position switches, independent of the fluid or pressure used. Gas venerator Anytime the valve leaves the closed 900 ball valve position, reaches the open position, and returns to the closed position, as Indicated by the valve position switches, independent of the fluid or pressure used. Engine control Anytime the valve is actuated and sub- 900 valve sequently deactuated as a result of the application of the required electrical) power to the start solenoid and stop solenoid, respectively. Ignition monitor Anytime the valve poppet is unlocked 400 valve and is unsented as a result of the appli- cation of the required actuation pressure to the control port, followed by return of the poppet to the normally closed posi- tion, independent of the fluid used. Jeniter fuck Anytime the piston is unseated as a result 459 valve of the application of sufficient actuation pressure tothe fuel inlet port, followed by return of the piston to the nurmally closed position, independent of the fluid used. eres nee ena, Le netemestebetoecomnamdeneheanecanitomernamnernmtentaneatomtameemertemeers term ees ree Figure 2-11. Tompenent Cycle Definition and Limits (Sheet 1 of 2) 2-26 re nr RAEI: mel NNR. Name Ne RET LO ll WN eves TR FORTE! EER AA SORT RORIN ATOPY OA 2 BA Bearing coolant control valve Redundant snutdewn valve Gimbal bearing Gimbal wrap-arcund lines Thrust OK pressure switch Checkout valve te et NY R-3896-11 Section II Cycle Definition Cycle Limit Anytime the coolant poppets and/or 900 preservative poppet are unseated as a result of the application of the reauired actuation pressure, followed by return of the coolant poppets and/or the pre- servative poppet to the normally closed position, independent of the fluid used. Anytime the valve is actuated and sup- 1, 900 sequently deactuated as a result of the application and removal, respectively, of the required electrical power to the redundant shutdown valve solenoid, Anytime one gimbal ac'uator is extended See figure 2-12. or retracted from its nominal position and returns to its nominal position is defined as halt a eycle, or anytime the thrust chamber centerline is displaced from its null position, travels in one square or circle pattern, and returns to its null position, is defined as one cyele. Anytime one gimbal actuator is extended or See figure 2-12. retracted from its nominal position and returns to its nominal position is defined as half a evele, or anytime the thrust chamber centerline is displaced fram its null position, travels in one square or circle pattern, and returns to its null position, 1s defined as one cycle. Anytime the diaphragm is provided suffi- 3,400 cient pressure so that electrical continu- ily is switched from the normally closed contact to the normally open contact, follawed by sufficient decrease in pres- sure so that electrical continuity is switched from the normally open contact back to the nermally closed contact. Anytime the checkoul valve actuator is 900 supplied with sufficient electrical power to cause the checkout valve ball to leave the "ground" position, reach the "engine" position, and subsequently return to the “ground'' position, as indicated by the valve position switches. ee Ne re Oe A OT ERLE Te CRE INRA PEA LTE OE Figure 2-11. Component Cycle Definition and Limits (Sheet 2 of 2) Change No. 6 - 10 February 1970 2-21 Ae er rae IR SE eT a aN ne OR ee ee eee menace eterna Foe a 902 Section IT R-3896-11 Paragraphs 2. 5.10.1 to 2.5.11 2.5.10.1 GIMBAL CYCLE LIMITATIONS, Cycle Limitations for the gimbal bearing and for wrap-around lines are presented in figure 2-12. In order to make sure that cycle limita- tions are not exceeded, a cycle ratio is con- puted to determine total cycles. A cycle ratio is defined as the ratio of the number of gimbal- ing cycles to the limiting number of gimbal cycles at a particular gimbal angular excursion, A formula to compute total cycle ratio fora particular gimbal excursion is provided as ———4 q faa | F : L- | =| area ot i int. 4 Le : iis os +— iE ice -+ te aioe ae Saati ‘am ho fo so onan oe PH prs } a ae 1 Teri Ss ba eee a8 sient ce ef og ee foll yd ete ollows: Saaepaeeenenn a x }! eda dq pa MM, My My M, trthip Hat te Per tnt tH tN tT < ] 42 tosh erpenfn « r+ poe Lh. i 1 2 3 n : ithe hy it im ace PERE Hebel p itd ‘ Pubs fda tye { i where on aaEAL REARING AND pees ; “ CTWRAP- AROUND LINES M, = number of cycles at X, degrees (Refer ta a eel ae Fneine Loy Book.) aI aoe ide oe aes oe N, = limiting number of cycles at x, degrees tL M, N.* cycle ratio 2.5.11 ENGINE CHECKOUT CONSTRAINTS, a. ‘The term "no leakage is allowable” is defined as bubble-tight for gas, and an unmeas- urable amount of lenkage over a 5- minute period when liquid is used. b. Unless otherwise specified, 2-5 minutes must be allowed for leakage observation on all tests that specify no leakage is allowable. c, tuez leakage is detined as a forraation of bubbles that do not increase in size over a 5- minute period, d, Leakage rates specified in this manual are at standard conditions of 70° F and 29,92 inches of mercury. e, Leak-test compound must not be applied to open ports or drain Hren curing leak tests. Figure 2-12, Gimbal Bearing and Wrap-Around f. Leak-test compound must be removed from Line Cycle Limitations engine surface at completion of leak teats, h. Electrical receptacles and plugs must be g. Inthe event a system is disturbed or inspected for damage, wear, and contamination opened subsesguent to completion of an authorized before comnections are made. leakage test, the leakage test muat be repeated on the disturbed or open joints, Whenever the i, When accomplishing authorized icakage 979 GG combustor to turbine manifold inlet flange isolation requirements, engine joints may be “*? has been disturbed or opened, an external leak- opened, as required, to isolate the specified age test of the joint shall be conducted, component, a- 28 Change No, 14 - 9 October 1972 R~-3896-11 j. The moisture content of the engine oxi- dizer propellant feed system and the heat exchanger GOX and helium discharge systems must not exceed 26,3 ppm by volume of water vapor corrected to standard conditions. k, If cngine systems are opened, the open-~ ings must be protected against entry of foreign material, and the moisture content of the sys- tem must be minimized tc satisfy requirements of step j, kA. When reinstalling a joint, verify that 902 all joint protective closures are removed prior # to reconnecting the joint. 1, The engine must be electrically grounded to a facility ground and any test equipment used, during all tests. m. Acceptable leakage rates as specified in test crileria are confined to those using Engine Contractor-provided or equivalent Stage Con- tractor test equipment. n. Leak testing of engine joints should be accomplished by completely covering fittings, seams, or joints with Icak-test compound (MIL-L-25567), Ifa leak is detected using a leak detector, verify leakage using leak-test *13eompound (MIL-L-25567) or by system isolation. o. When using a G3104 Flowtester to check leakage of joints incorporating seal monitoring ports and no leakage is specified, use tho smallest tube of the flowtester, The ball may move off the step but must not rise above the Clange No. 14 - 9 October 1972 Section IT Paragraphs 2.5.11,1 to 2.5.12 lowest graduation on the scale. which is tess than 0,25 scim when testing with gaseous nitro- gen or 0,29 scim when testing with helium, p. When a leak detector is used to detect leakage, refrigcrant, Type 12 (Federal Specifi- cation BB«F-1421), must be added to the system prior to the application of gaseous nitroven, 2.5.11.1 ENGINE CHECKOUT REQUIREMENTS AFTER _ STORAGE, When an engine is removed from s storage atte after being stored in accordance with Standard S-IC Stage Storage Specification MSiC-STD-500 for lime periods in excess of G months, checkout of the engine 1s required. See figure 2-13 for checkout requirements. 2,5,11.2 ENGINE CHECKOUT REQUIREMENTS AFTER STANDBY STATUS, Uninstalled flight spare and installed engines that are in standby 939 must be checked out as outlined in figure 2-134 before engine hot-fire operation. 2,5,12 ENGINE STARTING ATTIFTUDK CON- STRAINTS. For starting, the engine must be in the thrust-chamber-nozzle-duwn position with the thrust chamber centerline not exceeding a cant of 2 degrees, 30 minutes, from the true vertical, 2-2BA/2-28B Engine Status When Placed in Storage Completed Rocketdyne checkout, Completed single-engine recciving inspection, Completed single-engine cheekout. Cornpleted engine installation in stage, Completed stage static test. Completed stage receiving inspection, Completed stage post~static test checkout, Figure 2-13, Engine Standby Status Completed single engine checkout, Complete. stage post-static checkout. Completed vehicle checkout at VAB, R-3896-11 Next Planned Engine/Stage Operation Installation in stage, Installation in stage. Installation in stage. Stage static test, Post-statie test checkout. Post-static test cheekout, Shipment to KSC, ee tt an RN i nb Manne ns men msm Section TI ry Requirements (Figure PoE), Activities in event colurans § Aand B. Activities in event columns 4 A and B. Activities Jn event columns ' A and 3, Activities in event columns ; Hand J, Activities in event columns : N and O, Activities in event columns f N and O. Activities in event columns § Q, R, and ‘V through W. A ne es en eee ween a ingine Cherkout Requirements After Storage in Accordance With MSFC-STD-500 Requirements (Figure 1-1) Next Planned Stage Operation Stage static test, Vehicle launch, Stage static test. Vehicle launch. Stage static test, Vehicle launch, ee Activities in event columns ( H, J, and K, Activities in event columns § R, T, and W, Activitics in event columns | H, J, and K, Activities in event columns § Rand T through W, Activities in event columns § H, J, and K. Activities in event culumns U through W, Figure 2-13A, Engine Checkout Requirements After Standby Status Change No, 14 - 9 October 1972 2-29 950 Section If Paragraphs 2.5, 12A to 2.5, 18A fA 2.5.12A SLAVE TARDWARKE USE DURING E STATIC 1 TESTING OF OF E ENGINE AT MTF, During g static testing of engine at MTP, ‘slave | hardware y may be used in place of the standard hardware f supplied with the engine. The slave hardware ® and the constraints for using the hardware are fas follows: £ a. New hardware consisting of a thermocore A seal may he used in place of the delivered tadpole a cseal for the thrust chamber body to nozzle exten- g sion joint. # 6. Slave hardware, maintained in a clean % condition or cleaned to the requirements of H delivered loose equipment, consisting of the A nitrogen purge drain line and an AN fitting, f oxidizer overboard drain line and seai, and g fuel overboard drain line and seal, may be g reused unless damaged or deteriorated as de- a termined by visual inspection. ,» ¢. Slave attaching hardware, consisting of a clamps, nuts, bolts, and washers for installa- : tion of nozzle extension and drain lines, may Abe reused a maximum of three times unless 8 damage is indicated by visual inspection. : d. Slave hardware, maintained in a clean B condition or cleaned to the requirements of the fdelivered propellant feed system. consisting of pthe No, i fuel valve position transducer vent 7 drain tube for engines installed in the S-IC stage fin positions 103 and 104 and the No. 2 fuel valve f position transducer vent drain tuhe for engines # installed in the S-1C stage in positions 191, 102, Rand JO4, mar se reused unless damaged or f deteriorated as determined by visual inspection. 2 6c. 6Slave attaching hardware, consisting of B clamps, nuts, screws, and washers for installa- B tion of the No. 2 and No. 2 fuel valve position E transducer vent drain tubes, may be reused 4 unless damage is indicated by visual inspection. 2.5,13 GIMBAL LIMIT CONSTRAINTS. Engine ee displacement :nust be maintained within a equare pattern of plus and minus 6 degrees in the actuation planes from the delivered, alined engine position. Gimbal acceleration must not exceed combined longitudinal and lateral accel- eration of 0. 5y lateral and 10g longitudinal, 1.0g lateral and 6g longitudinal, or 2. 5g laterz] 2-30 Change No, 9 - 2 December 190 R-389s-11 and 3g longitudinal, Engine angular displace~ ment is limited to the longitudinal acceleration with an allowable displacement of 2 degrees at 10g, 4 degrees at Gg, 6 degrees at 3¢ with max- jmum angular displacement limited to 30 radians/second2. 2.5.14 HEAT EXCHANGER DRY-COH. TEST ING { CONS STRAINTS. If heat exchanger LOX or helium coils are to be run dry during engine testing, the coils must be provided with a 50 +15 psig purge of gaseous nitrogen (MIL- P-27401), 2.5.15 COCOON PURGE STUB LINE STATIC Th ESTING ‘CONSTRAINTS, The cocoon purge Stub [ine must be removed for engine testing unless the complete purge system, vonsisting of the wrap-around duct and manifold lines, is installed on the engine. 2.5.16 FIREX CONSTRAINTS, A gaseous a or water system rust be supplied to protect the engine in the event of fire and to control chamber afterfire following engine cut- off. In the event of fire, water should be di- rected on the engine only in an emergency. 2.5.17 THERMAL INSULATION REQUIRUE- MENTS. Thermal insulation is provided for flight testing the F-l engine. Engine static tests may be conducted without thermal insula- tion if the engine ambient temperature require ments for engine Starting are met. An engine equipped with the bracketry for thermal insula- tion (figure 2-14) and/or equipped with LOX propellant feed systein insulation may be static tested i{ the engine armbicnt temperature re- quirements for engine blarting are inet. Bigure 2-15 Hsts and locates the thermal insulation access doors. Therma! insulation damage limits are specified in figure 1-4, (A remereitmeatemenern nine prewar ELECTRICAL Sz on FETY raRCUTT RE REGUIRES MENTS, “The engine electrical control system sequencing and safety circuit requirements are shown in figure 2-16, 2.5,18A. FLIGHT INSTRUMENTATION SY8- TEM VOLTAGE LIMITS. Vhe fight instrumen- tation system voltage limifs presented in figure Z-16A are used to determine initial pressure tansducer data for those instruments for which no data is available inthe Engine Log Book, ays 19 R-3896~-i1 Section IT Paragraph 2.5.19 Serhan AR LAR NTN ReTmREeceNRL ae 8 SRRTU “ERLE a CW Oe HON outlined in figures 2-17 and 2-18. Instrumenta- Lion requirements for launch are outlined in fig- ures 2-19 and 2-20. Definitions for interpreta~- tion of the instrumentation (~bles are as follows: a. The category column letrers M and HD on the uistrumentation tables are defined as follows: (1) The letter M is defined as mandatory. A mandatory item is an engine element or an operational support element essential for the accomplishment of test or launch, which includes pre-test, static test, prelaunch, and launch. If a mandatory item fails deving countdown, it must be corrected prior to static test or launch. (2) The letters HD are defined as highly desirable. A highly desirable item is an engine or operational support eloment that supports and enhances the accomplishment of the test or launch. Consideration must be given to the re- pair of any highly desirable item that fails, but in no case must the static test or launch be scrubbed for any single failed item. b. Any function that is interlocked for an automatic sequencing device that will affect an automatic shutdown or will prevent static test or Jaunch completion is defined as mandatory. c. AJl redlines (minimum and/or maximum values or conditions) are mandatory. Verifica- tions that the values or conditions remain within the limits of acceptable operation specified are mandatory, (1) Minimum and/or maximum yaluas are mandatory and are assigned to any engine cle- ment or operational support element required io meet a specified condition in order to gain maximum assurance of acceptable system per~ formance. It is mandatory that at least one method exists for verifying each redline. Change No, 6 - 10 February 1970 2-30A/2-30B R- 3896-11 section Il FRAME ASSEMBLY \ EN SUPPORT fe a —s ee nee 7 4, be 4 the 3 . ico eh : st a ae et ACKET SECTION A-A - : F ot, ass, a m* f i toe A) HRACKET-~- vay Fi-11-97 Figure 2 2-14, Thermal Insulation Installation Requirements Prior to Stage Shipment to KSC 2-31 Seetian Ef R-3896- 11 i : ‘ac Ca \ = i N THRUBT CHAMBER AND NOZZLE EXTENSION Figure 2-15, Thermal Insulation Insulator Access Doors (Sheet 1 of 2) R-3898- 11 Section 1 Index No, Access to Index No. Access tou COCOON AREA Ignition monitor valve quick-dis- . a) connect i Thrust OK pressure switthes and oxidizer dome purge and flush port 13 No. 2 main fuel valve purge quick- disconnect 2 No. 1 oxidizer dome flush and purge ports 14 Hypergol cartridge container 3 Hypergol purge quick-disconnect 15 No. 2 thrust chamber fuel inlet mani- fold quick~digsconnect 4 Hyperpol drain quick-disconnect 16 Engine hydraulic supply and return 5) Checkout valve line quick-disconnerts 6 No. 2 oxtdizer dome flush and purge 17 No, 2 fucl high-pressure duct drain ports quick- disconnect t Gas penerator oxidizer purge check 18 Instrumentation valve 19 Turbopump torque adapter and No, 2 8 Gas generator ipniters fuel turhopump inlet drain quick- disconnect 3) Gas generator drain 20 Oxidizer dome flush and purge port 10 No. { fuel high-pressure duct drain quick- disconnect THRUST CHAMBER AND NOZZLE EXTENSION AREA 11 No. 1 thrust chamber fuel inlet manifold drain and No. 1 main fuel valve purge quick-disconnects 21 Thrust chaniber drain aud noazle extension igniters 22 Thrust chamber drain (3 places ) (a) Thermal insulation sets 18-5 and subsequent L eeemetetiiieemesenmiel ee EHD, Figure 2-15, Thermal Insulation Insulator Acces» Doors (Sheet 2 of 2) Section II R-3806-11 Turbopump heater power Checkout valve ground position No, 1 and No. 2 main oxidizer valve closed Gas pencrator ball valve closed No, land No. 2 inain fuel valve closed (©) Hypergol installed switch Gas generator and nozzle extension igniter power (a Gas yenerator aye nozale extension igniter links (@){k Engine control valve start signal Pressure switch piekup"? Engine coutrol valve stop sigaal Redundant shutdown valve Vibration safety cucoff ——+ a ee Cutoft Post- Shutdown | Pre-Start |Transition Operation Start ee {a) (b) (f) (i) (h) (i) (i) (I) fa) During enzine static testing or launch abort, heater power must be durned on at engine control (I>) («) 2-34 valve stop signal and must remain on until all LOX has been removed from he engine. During engine start, heater power may renin on until static lest or launch comimlt. Prior to the mitiation of aulomatic sequence, the checkout valve must have been previously cycled to the engine position with fuel dn the engine and a ground nydrautic supply pressure of 1,550 4100 psig, tor atleast 20 seconds without subsequent drasnage of the checkout valve to inet elbow hydraulic velurn hose. During the automatic sequence, the checkout valve inust be in the engine position for at least 20 seconds prior to engine start signal and the igniters must not be fired unless the checkout valve is in the engine position. An engine test must be terminated Hf: (1) both rain fuet valves ieave the closed position prior lo loss of hypergol installed switch signal; (2) one main fuel valve reaches the open position while the other matn fuel valve has not left the closed positton; (3) both main fuel valves leave open pouition during a stayre-static test. Gas gencrator and nozzle extension igniter power orast be supplied fur 0. 100 40,050 second, aud the engine control valye slart signal must ecenr le 5 seconds after lgniler power has been Inithated, A. test must be terminated if at least ove pag generator igatter Link and one nozeie extension igniter Lak have not brokan by the time the enine contiol valve start shun! is initiated, The engine control valve start signal must be applied for @, 700 sevond minimum, An engine test must be terminated if at least 2 of 3 thrust OK pressure switches have not picked up whea checked after 5.9 seconds (at standacd Inlet conditions specified in £-1 Engine Interface Document R-6749) after engine control valve start sipual has been initiated, The enzine control valve stop sisnal must be applied for 0. 106 second minimum, The redundant ghutdown valve signalannet be applied for amininium of 2 minutes and‘a maximum of 15 minutes during enpine static testing ur iu ithe event of launch abort. During flight, the sig- nal must be applicd simultaneously with cngine cutoff signal aud be inaintained through stage sep- aration. Power must also be applied to the redundant uhutdown valve after cutoff if power is appltedtuthe engine control valve start solenoidfo prevent main engine valves from opening, ee ea a ee ee em ER I NN RY OG AN OE I Nl SE mY eR He RU gh wt = NE “Ph Figure 2-16, Electrical Coatrol system Sequencing and Safety Circuits (Sheet 1 of 2) Change No. 6 - 10 February 1970 R-3896-11 Section If (j} External control of the engine start and engine stop solenoids must be such that an engine start solenoid cannot be energized unless continuity to the stop solenoid connector exists. (k) A test must be terminated any time the pas generator and nozzle extension igniter link mdicate iinks open subsequent to attaining an igniter installed indication with 28 vde power applied to the igniters and prior to high voltage application to fire the igniters. (1) A stage-static test must be terminated any time 2 of 3 vibration safely cutoff units indicate vibration levels in excess of those specified in F-1 Engine Interface Document R-6749. Figure 2-16, Electrical Control System Sequencing and Safety Circuits (Sheet 2 of 2) Voltage Limits(2) Low Righ Calibrate Calibrate a anew High Initial Tap Parameter High Pressures LBla LOX pump bearing jet ~0.125 A275 275 4.275 GGld Gas penerator chamber -0.150 0,250 4.250 PF2a-2 Fuel pump discharge No, 2 ~0.170 | 0.230 ; 4,230 NH5c Common bydraulic return -0.050 | 0.350 4,350 CGle Combustion chamber ~0.150 | 0.250 | 0.850 4.250 vF2a-1) Buel pump discharge No. 1 | -0.170 | 0.230 | 0.630 | 1.230 4.230 NH3alb) Engine control opening ~0.170 0.230 | 0.8380 [ 1,230 | 3.830 4.230 poza-t! LOX pump discharge No. t | -0.160 | 0.240 | 0.840 | 1.240 | 3.840 | 4.240 NH2a!?? Bagine control closing «0,170 0.230 | 0.830 | 1.230 | 3.830 4.250 potalb) LOX pump seal cavity 1.750 | 2.150 | 2.750 | 5.150 | 5.750 HH2a(P) Heat exchanger helium 0.050 } 0.350 1.350 | 3.950 | 4.350 outlet HH2al?) Feat oxchanger helium ~0, 050 3.950 4.340 inlet Ho? Heat exchanger LOX inlet -0.160 | 0.240 | 0.840 3.840 | 4,240 HO4alv) Heat exchanger GOX vutlet -. 160 0.240 | 0.840 3,840 4.240 KF6a-1 Fuel pump inlet No. 1 0,150 0.600 | 1.150 4.150 4,600 PORa-2 LOX pump discharge No. 2 ~0.160 | 0.240 | 0.840 3,840 4.240 ing test. Pressures outside these limits have a significant effect on the limits. (b) Engines uot incorporating MD96 change Demmi ieperierieectntmmereeiearienemic coir oe eehenna a a ee ee Figure 2-16A. FlHgut Instrumentation System Voltage Limits AACA OT RATE ARE el EC COE ARS LE A Pay ree ot N AO NRNn E, 2-344/2-34B R~ 3896-11 (2) A category of mandatory assigned ta a measurement agsociated with a redline indicates that the measurement is primary for monitoring the redline and must remain operational since no other means exists to verify that the redline is within the specified limits. (3) Unless otherwise specified, the redlines as listed apply to each engine. 2.5.20 DETERMINING ACCEPTABILITY OF WETTED SURFACE LEAKAGE, In the event surface wetting is observed on any Component in the engine hydraulic control system, deter- mine if the condition is acceptable as follows: a. Wipe wetted surface clean with a ctoth de mpened with cleaning compound (Mslu-C-81302), or equivalent. WARNING Cleaning compound (MI.-C-81302) is volatile. Use in a well-ventilated area since the vapors displace the oxygen inthe air, resulling in suffocation. b, Pressurize engine hydraulic cantrol sys- tem to 3-30 psip. c, Observe surtace for evidence of leakape. Meosurface wetling reappears wathin 5 minutes, wipe wetted surface clean and inspect surface witer another S-aninute interval, co necessary, repeat step ¢ four more times (a total of 5 limes). If surtace wetting continues followiny, the 5 inspection intervals, reject the component. ff surfoce wetting does not appear tollowlng any 5-imiuule inspection interval, proceed ta step a, e Increase hydraulic system pressure to 1,400-1, 600 psift. f. If no surface wetting appears within 5 min- ules, the camponent is acceptable. I surface wotting appears willin 5 minutes, wipe wetted surface clean and inspect aller another 5-minute intervai. g. If necessary, repeat step f four more times (a total of 5 limes), If surface wetting contipues following the 5 inspection intervals, reject the component. If surface wetting does not appear following any 5-minute inspection interval, the component is acceptable. Section I Paragraphs 2.5.20 to 2,65,21 2.5.21 FUEL OVERBOARD DRALN SYSTEM ISOLATION REQUIRE! MENTS. a. Unless otherwise specitied, any time an unlastalled engine is in a vertical position, the fuel overboard drain line at the thrust chamber exit must be open to ambient environment, b. Prior to engine rotation from the vertical to the horizontal position for installation in the 8-IC stage, the fuel averboard drain system must be isolated as follows: (4) The cross-to-lateral fuel overboard drain tube must be disconnected from the Y-fitting on the fuel oyerboard drain line. (2) The No, 1 fuel valve position trans- ducer venl drain tube must be removed between the fuel valve and the tee for engines to be in- stalled in the §-IC stage in positions 103 and 104. (3) The No, 2 fuel valve position trans- ducer vont drain tube must be removed between the fuel valve iiuid the tee for engines to be in- stalled in the S-{C stave in positions 101, 102, and 105, 901 (4) A clean polyethylene bag (one gallon nuinkimum volume) must be installed on vach side of the diseonnections Listed in substeps 1 through 3. The bugs mint allow free flow but prevent the entry of contaminants, Bags must be se- cured in a manner (hat allows rotation of the engine from horizontal te vertical wilh the bags fled with fhuid (b) The cover must be installed on the fuel overboard drain line at the thrust chamber exit. c. Twenty-four houes after completion of in- stallation of haps, the bugs must ve inspected for fluid collection, Of Muid is evident, the bags must be removed and quantity of fluid measured, New bags must be installed on joints and iu- speetion and fluid volumetric determination re~ peated 24 hours Jater. Determine subsequent inspection (ime (maximum intervals, 30 days) using the following formula: Day joa Noliee) Day 2 vl (60) 1. days) 2 3,764 ce If fluid is not evident in the bags after the first 24-hour inspection, subsequent bag inspections must be performed at 30-day intervals. Change No. 5 - 9 October 1969 2-35 Sectien I Paragraphs 2.&.22 to 2.5.22.1 d. During S-IC stage rotation from horizontal to the vertical position, the thrust chamber and exhaust manifold must be monitored for fluid drainage, Fluid drainage is not allowable. e, After completion of S-IC stage rotation to the vertical position, the fuel overboard drain system must be restored as follows: (1) The cover must be removed from the fuel overboard drain line at the thrust chamber exit, (2) A clean polyethylene bag (one gallon minimum yohune) must be installed on the fuel overboard drain line at the thrust chamber exit, The bay must allow free flow but prevent the entry of contaminants, The bag must be re- moved prior to engine static test or launch, (3) The bags must be removed from the cross~to-lateral fuel overboard drain tube and the Y~fitting on the fuel overboard drain line, and the tube reconnected to the Y-fitting, 901 2-36 (4) The bags must be removed from the tee and the fuel valve, and the No, 1 fuel valve position transducer vent drain lube reinstalled for engines installed in the S-IC stage in pasi- tions 103 and 104, (5) ‘The bags must be removed from the tee and the fuel valve, and the No, 2 fuel valve position transducer vent drain tube reinstalled for engines tnstalicd in the 8-1C stave in posi- tions 101, 102, and 105, f. Prior to §-I1C stave rotation from vertical to the horizontal position, or in the event an installed engine is in a horizontal stage and the fuel overhoard drain system is nol isolated, the fuel overboard drain system must be iso- lated an follows: (1) ‘Phe cross-lo-lateral fuel overboard drain tube rust be disconnected From the Y-filting on the fuel overboard drain line. (2) ‘The No, 1 fucl valve position trans- ducer vent drain tube must be removed between Chauge No. 5 - § October 1969 R-3896-11 the fuel valve and the tee for engines installed in the S-IC stage in positions 103 and 104, (3) The No. 2 fuel valve position trans- ducer vent drain tube must be removed between the fuel valve and the tee for engines installed in the S-IC stage in positions 101, 102, and 105. (4) A clean polyethylene bag (one gallon minimum volume) must be installed on each side of the disconnections in substeps 1 through 3. The bags must allow free flow but prevent the entry of contaminants, Bags must be se- cured ina manner that allows rotation of the engine from vertical to horizontal with the bags filled with fluid. (5) The cover must be installed on the fuel overboard cirain line at the thrust chamber exit. gg. ‘Twenty-four hours after completion of installation of bags, the bags must be luspected for fluid colluetion. If fluid is evident, the bags must be removed and the quantily of fluid measured, joints, and inspection and fluid volumetric doe- termination repeated 24 hours later. Determine subsequent inspection time (maximum intervals, 30 days) using the following formula. Vee) 4 Day 2 vol (c ig). 2. Day 1 vo (x days) = 3,764 cc If fluid is not evident in the bags after the first 24-hour tnspection, subsequent bay inspections must be performed at 30-day intervals. 2.5.22 FURL FEED SYSTEM DRAIN REQUIRE- MENTS. 2.5.22.1 Uninstalled Engine, Vertical Position, Prior to opening engine propellant valves, drain hoses must be installed on the drain quick= disconnects of the No. 1 and No, 2 fuel high- pressure ducis, gas generator ball valve inlet, turbopump No, Land No, 2 fuel inlet elbows, engine control valve supply tube, and checkout New bags musl be installed on 901 R-3896-11 vaive engine return hose, and fuel allowed to drain. Drain hoses must be attached to the en- gine control valve supply tube and the cheekout valve engine return hose quick-discunnects until after completion of all engine propellant valve actuations. Ifa gimbal system is in- Stalled on the engine, the drain hose must be attached to the Na. | fuel high-pressure duct quick~-disconnect until the hydraulic control system pressur¢ is decreased to ambient. Prior to each engine propellant valve actuation drain hoses must be installed on the drain quick-disconnects of the No. 1 and No, 2 fuel high-pressure ducts, checkout valve enyine return hose, and gas generator hall valve fuel inlet, and fuel drained prior fo valve actuation. Hoses must be left attached until after comple- tion of valve actuations, 90% 2.5,22.3 Installed Kngine, Horizontal Position, Priur to each engine propellant valve actuation, _ the plugs must be removed from the following engine instrumentation taps and fluid allowed to drain. The taps must be left open until after completion of engine valve actuations, 2,5,22.2 Installed Engine, Vertical Position. Instrumentation Engine Position Taps Kifectivily KEGd-2 102 Kifa+1 103 1F2 101 and 104 PR3a~-2 107 and 105 NOTH A suction pump inust be used to re- move residual fluid frorn PFSa-2, Section II Paragraphs 2.5.22,2 to 2.5,23,2 2.5.23 ENGINE REQUIREMENTS APTER A LIGHTNING STRIKE, Engine requirements after a lightning strike are predicated on data from instrumentation that monitors stage and ground AC and DC voltage and current supplies to the engine; data anomalies noted during the lightning strike; and the engine condition after the light- ning strike, For this requirement a data anom- aly {s defined ag any fluctuation in voltage or eurrent level that cannot be attributed to normal system operation, Paragraphs 2,5,23.1 and 2,5.23.2 contain engine requirements for the conditions specified, 2.5,23,1 Instrumentation Monitored and No. ae ee Data fa Anomalies Noted Buri ing Lightning S Strike, Visually inspect the engine for obvious Uehtning strike darnage (eg, burned or heat-diseolored thermal insulation), If damage 1s noted, per- form maintenance, testing, and servicing tasks required to return the engine to a flight condition. »5,28,8 Instrumentation Not Monitored dor ee ne es ee lninoiitit Monitored and Data Anomalies Noted During Cightning Strike. Visually inspect the engine for obvious Vyrhtning slrike damage (cg, burned or heat-discolored thermal insula- tion) and verify requirements, specified in steps a through d, If damage fs noted cr engine falla to meet the requirements, perform maintenance, testing, and servicing tasks required to return the engine to a flieht condition, O36 NOT! Measurements may be taken from casily accessible ground terminals, a. HWngine control valve: {1) Start solenoid coil: 55 27 ohms. (2) Stop solenoid coll: 55 +7 ohms, b. Redundant shutdown valve aclenoid call: 18.4 46 ohms. Change No, 14 - 9 October 1972 2-36A Section II R-389R-11 Paragraphs 2.6 to 2.6.3 c, Checkout valve: (L) Actuator motor windings: 15 ohms maximum, O56 (2} Open switch: 15 ohms maximum, e (5) Closed switch: 15 ohms maximum, d. Thrust OK pressure switch pic«up and dropout values within Hmits specified in section 1, 2.6 DOCUMENTATION REQUIREMENTS, 2.6.1 ENGINE LOG BOOK ENTRIES, An En- vine Log Bool must be maintained for each en- gine to provide accurate and current records of engine configuration, tests, operaling time for engine and components, oriilces sizes, engine mainterance, and serlalized components as instalied. The custodian of the engine must maintain the Engine Log Bouk and verify that entries are made for each sertalized component replacement, variable orifice replacement, and other maintenante and test data, The Engine Log Book must accompany the engine whenever engine custody is transferred, . 2, 6.2 UNSATISFACTORY CONDITION REPORT SUBMITTAL, An Unsatisfactory Condition Report (UCR) must be prepared to report all unsatisfactory conditions on a part, component, engine, or technical document. Information detailing the fallure and its test history thet is required to complete the UCR should be pro- vided, if appHeable, by the Stage Contractor to the Engine Contractor. In the event the falled component is removed from an engine, the failed component must be returned to the Engine Contractor for fiilure analysis, 2.6.3 CHECKOUT DATA, During the perform-~ ance of authorized tests specified In section I, the test results must be recorded and submitted to the Engine Contractor upon requent, 2-36 Change No. 14 ~ 9 October 1972 R-3896- 11 2.6.4 STATIC AND FLIGHT TEST DATA, 2.6.4.1 Engine Redline Parameters, The en- gine test data on which engine redline para- meters were recorded must be examined to determine whether any engine system is per- forming near its minimum or maximum estab- lished limit. If an engine system with an cs- tablished operating limit is performing near its operating Hmit, Engine Contractor must be notified of this condition prior to the next test. 2,6,4,2 Test Instrumentation, All test In- strumentation that monitors any engine para- meter ona high-frequency, oscillograph, or scated system must be examined for abnor« mailties, such as sudden shifts in any one cr ee Section H Daragraphs 2,6.4 to 2,6.4.4 a combination of parameters, abaormal feed system oscillations, abnormal feed system oscillation arapliludes, or abnormal vibration levels, A diserepancy in any lest parameter must be reported to Engine Contractor, 2.6.4.3 Data Keduction, Those engine test parameters that are recorded and used to es- tablish engine calibration must be reduced to Standard sea-level conditions, and the results must be submitted to Engine Contractor. 2.6.4.4 Data Interval Definition, The data in- terval is defined as a period of 3.0 to 3.2 sec~ onds within the time interval of 35.0 tu 40.0 seconds after attainment of mainstage (90 per- cent of thrust). firroy Identification/ (Percent | Gi aoor Instrumenta- Parameter Calibration of Full atcgory tion Tap Description Range Range) M iz ‘Lime Period/Action/Notes KF6a-] Fuel pump 0,200 psie 12.0 inlet No, 1 TG5e Turbine 0-100 psig 12,0 outlet DPF2n+2 Fuel pump )-2, 590 12.0 discharge psla No. 2 CGJea Combustion = 0-1, 900 40.56 chamber psia GG1ld Gas poneray U-1,500 1,0 tor chamber — psia terete sks es crete ere canine PRIMARY FLIGHT INSTRUMENTATION Ses A Fe ee eR RN Ae nth FN AD TS RE REA ie He a mc me Weure 2-17, Static Test Instrumentation Category Itequirements (Sheet Lot ) Fuel pump inlet pressure measure- ment is wso provided by stape- statie-test Listrurmentation taps K¥Gb-1 and KF6d-2, One of the measurements must be classifled as mandatory. and the other two classified as highly desirable, See notes. Fue} punp discharee pressure measurement is also provided by wuxiliary flight instrumentation tap PF2a~-) and slape-statie -test instrumentation taps PF2b-1L and Pr2h-2, One of the measurements must be classified as mandatory, and the other three classified as highly desirable, See notes. x ee Change No, 14 - 9 October 1972 2-360 /4-36D R-3896- 11 Section If mieenimnanaae re erent a Aen et Seen Brror identification/ (Percent | ostesor Instrumenta- Parameter Calibration or Full —— Time Perlod/Action/MNotes tion Tap Description Range Range) | M | HD ree am errs naeenemmnrwemresorvermmamacamininiens wf»: PRIMARY FLIGHT INSTRUMENTATION (cont) PO2Za-2 LOX pump 0-2,000 12.0 See notes. LOX pump discharge pressure discharge psia measurement is also provided by No. 2 auxiliary flight instrumentation tap PO2a- 1 and stuge-static-test in- strumentation taps PO&b- 1 and PO2b-2, One of the measurements must be classified as mandatory, and the other three classified as highly desirable, NHASe Common hy- 0-500 psia = +2.0 xX draulic relurn LBla LOX pump Q- 1, 000 12.0 Sec notes. LOX pump bearing jet pressure bearing jet pstia measurement is also provided by glige-static-test instrumentation iap LUAh. One of the measure- ments must be classified as manda- tory, and the other classified as highly desirable. LSL LOX pump 0° ta 42.0 Xx Measurement ray be classified as bearing 400° F highly desirable &f turbopump bear- No. 1 ing thermostat T3 is used as an interlock. veda) Turbine 0” to +2.0 See poles, ‘Turbine inlet temperature is also inlet 2,000° F provided by Stage- supplied Qinanifold) measurenent at tap GG2b. Que of the measurements must be classi- fied as mandatory, and the other classified as highly desirable. Kb Gas generar On-off =" See notes, Closed puogition is classified as tor ball valve (open- mandstory, and open pusjtion is limit switeh — closed) classified as highly desirable. Identification K6 is an MSEC number reference, K? Fuel valve One off - x Identification KT js an M&&C No, i Umit (open- number reference, switch closed) Fuel valve 0+ 100%, - K No. 1 posltion (a) Engines not incorporating MD176 change Ler Reel ya lee 9 yr A Re ee Set SE See notes. Closed position is classified as Valve No. 1 (open- mandatory, and open position is limit switch — closed) Classified as highly desirable, Oxidizer G-100% -- X = Identification KD is an MSFC valve No. L number reference, pasition K10 Oxidizer On-off -- See notes Closed position is classified as valve No. 2 (open- mandatory, and open position is limit switeh closed) classified as highly desirable. Oxidizer 0-100", as x Identification KIO is an MSFC valve No, 2 number reference. position Th Turbopump — 0-7, 000 -- x RPM No, 1 is an ae cyele count pm No, 1 rpm {0-234 cps), Identification Tl is an MSFC number reference, Turbopump 0-7, 000 iad x RPM No, 2 is an ae cycle count rpm No, 2 rpm (0-4, 200 eps). F44 Heat ex- 20- 100 12,0 Xx Identification F44 is an MSFC changer gpm. number reference, LOX inlet Now COT} Enyrine en- 0” to. 12.0 Xx [denlification CGT 1s an MSEC vironmental 1, 500° F nuniber reference, temperature ot , Q ihe 1,000° F (aA) AUXILIARY FLIGHT INSTRUMENTATION Auxillary flight Instrumentation is not applicable on engines incor- porating MD96 change. PPea-1 Fuel pump 0-2, 500 42.0 See notes. Fuei pump discharge pressure is discharge psia also provided by primary flight in- No, t strumentation lap PF2a-2 and stage~static-test instrumentation tups Pr2b-l and PF2b-2. One of the measurements must be classi- fied as mandatory, and the other three classified as highly desirable. saetete 2-38 Change No, 6- 10 February 1970 R-3896-11 Secetlon I Identification/ (Percent Instrumenta- Parameter Calibration of Full tion Tap Description Range Range) ‘Time Period/Actlon/Notes AUXILIARY FLIGHT INSTRUMENTATION (cont) PO2a- 1 LOX pump 0-2, 000 £2,0 See notes, LOX purip discharge pressure discharge psia measurement is also provided by No. 1 primary flight instrumentation tap PO2a-2 and stage-Static-test in- strumentatlon taps PO2b- t and PO&%b-2, One of the measurements must be classified as mandatory, and the other three classified ag highly desirable. NH3a Engine con- 0-2, 500 +2,0 Xx trol opening psia NH2a Engine con- 0-2, 600 +2.0 See notes. Control system supply pressure trol closing pula measurement provided by stage- statle-test instrumentation tap NH 1b rnay be used in ileu of engine control closing pressure, Engine control closing preasure is algo provided by staye-static-test in- strumentatlon tap NH2b, One of the measurements listed must he classified as mandatory, and the other claasified as higtly desirable. All measuremeats may Ve classified as highly desirable if a facility- supplied hydraulic pressure umbili- cal connection 18 operational, HOLD Heat ox- 0-2, 000 £2.0 x changer psia LOX Inlet HO4a Heat ex 0-2, 000 42.0 Xx changer psia GOK outlot HH2a Heat ex- 0-500 12.0 x changer hee = psia llum inlet HH8a Heat ex« 0-500 £2,0 x changer he- — psla kum outlet POQTa LOX pump 0-60 £2,0 Seenoles. LOX pump sel cavity pressure Beal cavity paia measuremeout ig also provided by stage-slatic-test instrumentation tap PO7b, One measurement must he classified as mandatory, and the other clagseified as highly desir- able, ’ . eiasetienbathatniaithamichahentinehel aetntetetaentemee chdetemesteiemnsen aeniadeaaden cemmeaetnantnentedaenmadnen a atadede atu aiteraatt rand Figure 2-17, Static Test Instrumentation Category Requirements (Sheet 4 of 9) Section it ee en ene Identification/ Instrumenta- tion Tap HOla HOdb HH 3b goo KF 6a-2 a KF6b-1 98k F6d-2 PF2b-1 PF2b-2 PCb~ 1 PO2b-2 CGIb Parameter Description Calibration Range R- 3896-11 Error {Percent of Full Range) Category AUXILIARY FLIGHT INSTRUMENTATION (cont) Heat ex- changer LOX inlet Heat ex- changer GOX outlet Heat ex- changer he- lium outlet Fuel pump inlet No, 2 -300° to -250° F -300° ta +600° F ~300° F to +600° F +2.0 +2.0 12,0 0° to 180° F 42.0 STAGE STATIC TEST INSTRUMENTATION (i>) {c) (b) (c) (b)(c) (b)(c) (ib) (c) cargo) Fuel pump inlet No. 1 Fuei pump inlet No. 2 Fuel pump discharge No, 1 Fuel pump discharge No. 2 LOX pump discharge No, 1 LOX oump discharge No. 2 Combustion chamber No, 1 Combustion chamber No, 2 0-250 psia 0-2, 500 psia 0-2, 000 pela 0-1, 500 psia 0-1, 500 psia 10.5 +0.5 40,5 0.5 10,6 tb) Engines not incorporating MDI141 change (c) Engines incorporating MD150 and MN151 changes — 2-40 Change No, 6 ~ 10 February 1970 Sce notes. See notes. See notes. Figure 2-17, Static Test Instrumentation Category Requirements (Sheet § of 9) Time Period/Action/Notes Fuel pump inlet pressure mcasure- ment is also provided by primary flight instrumentation tap KF6a- 1, One of the measurements must be classified as mandatory, and the ather two classified as highly desirable. Fuel pump discharge pressure measurement ts also provided by primary flight instramentition tap PF2a-2 and auxiliary flight instru- mentation tap {¢Fda-1, One of the measurements must be classified as mandatory, and the other three classified as highly desirable. LOX pump discharge pressure measuremeut Is algo provided by primary iustrumentation tap PO2a~2 and auxiliary flight instru- mentation tap PO2a-1. One of the measurements niust be classified as mandatory, and the other three clussified ag highly desirable. R- 3896-11 Section Ti EN re rece Error Identification/ (Percent : Instrumema- Parameter Calibration of Ful: Category tion Pap Neseription Range Range) Time Period/Action/Notes STAGE STATIC TEST INSTRUMENTATION (cont) GGib Gas genera- 0-1, 500 40.5 x tor chamber psia TGba Turbine O- 109 +0.5 x outlet psia NHap®)(4) Rugine con- 0-2,000 12.0 See notes, Control system supply pressure trol closing psia measurement provided by stage- static-test instrunientation tap Niflb may be used in lieu of engine control closing pressure, Engine control closing pressure measure - ment is also provided hy auxiliary flight instrumentation tap NH2a. One of the measurements listed must be classified ig mandatory, and the other classified an highly desirable. NH4b(b)(d) Engine con- 0-2, 000 12.0 4 trol opening = psia NH8 Redundant -2, 100 12.0 Xx shutdown pslu valve 909 supply [ pressure LBlb LOX pump 0-1, 000 +2.0 See notes, Two transducers are provided on bearing jet pata hae incorporating MD150 and MD151 changes. LCX sump bear- {ng Jev pregsure measurement 1s also provided by pritcary tnstru- rmientation tap LBla, One of the measurements must be clasulfted as mandatory, and the other clacsl- fied as highly desirable, Priotb)(d) Fuel impeller 0-500 12.0 See notes. ‘Two transducers are provided for bavkcasing psla this measurement. One must be classified as mandatory, and the other Glausifled ag highly desirable, nub )(e) Control sys- 0-2, 000 $2.0 See notes. Engine control closing pressure tem supply psla provided by stage -static-tost in- atrumentation tap NW@b or auxil- lary fUght Instrumentation tap Nii2Za may be used tn lieu of conteol system supply pressure. One of the measurements sted must be claustfied as raandatory, and the other classified a4 highly desirable. (b) "Engines not incorporating MD]4 charge c) Engines incorporating MDI50 anc MOT51 changes d) Engines not incorporating MDI51 chasdige ~ ee a NNR ANY SR a A Nein NO ame Gam wD Teoemeainedien Lorie ho hetaeeeriemmamnae herae icatadte, omeremnmem enema nensaneannn natanabaed te Se stetehediadhutdinteimmaamteiannamnaatenel Figure 2-17. Static Test Instrumentation Category Requirements (Sheet 6 of $1) Change No, 6 ~ 10 February 1970 2-41 Section I ome ewen Ideni:fieation, Jnetrumenta- tion Tap ssierstensier mnie maamesdnanch aluostedubbenmietieiehieaietenta Parameters Description Calibration Range Error (Percent al Full Range) R~3896-11 STAGE STATIC TEST INSTRUMENTATION (cont) rom) GCéa PZAS-2 PZA4 ke PZAR- y PAAIeF CZAI-¥ CZAI-¥ CZA10-¥ POad- 1 (b) “Engines not ‘Incoporating MD141 change LOX pump geal cavity Turbine intet 0-80 psig 0-1, 500 psig 42,6 40.5 Sce notes, ¢ Time Period/Action/Notes Two transducers ere provided on engines invorporating MDIS0 and MD151 changes. LOX puimp seal cavily pressure measurement is also provided by ausiliary flight instrumentation tap POTa, One ineasurement must Le classified as mandatory, and the other clagsi- fied as highly desirable. LSI MONTSORED) INSTRUMENTATION PARAMETERS LOX pump inle: Hange Fuel purap inlet elbow Fuel pun.p inlet elbow Fuel pump inlet elbow Fuel pump housing Fuel pump housing Gas gear ra- tor combustar Gas genera- tor combustor LOX dome LOX dome LOX dome 1.0% purap inlet LOX pump discharge No, 1 N-259¢ 0-250¢ 0-259¢ 0~250¢ 0 250¢ 0-250¢ 0- 300g ~ 5005, fr 70" 0-707 pg 0-70%¢ 0-200 psia 0-2, 000 psta amar (c} Engines invorporating MDISG and MO1S1 chang3s ache sea ee flim ym & x 0-3, 500 cps fliler 0-3, 500 cps filter Triaxtal mounting gad 0-3, 600 cos Trioxtal mounting pad 0-3, 500 cps Trisxial mounting pad 0-3, 500 cps 0-3, 500 eps Adapter block (Y) 0-3, 500 cps Adapter blovk (2) 0-3, 500 cps dc to 10 ke sédb de to JC ke +2dhb dc to 10 ke +2dn de to 10 ke 4£2db de to 10 ke 42db RCO 9 Ce UT Oe AR LOOT: Pipe 2-17, Static Test Instrumentation Category Requirements (Sheet 7 of &) R-3896-11 Section i RN eo a SE Tl A A ee eee ay pe ee ee ee ee Error Identification/ (Percent r : | Instrumenta- Parameter Calibration of Full SeieEOry. tion Tap Description Range Range) M | HD Time Period/Action/Nutes C eenatenaad tin EE SD EN EE di ENGINE- MONITORED INSTRUMENTATION PARAMETERS (cont) PO2%cCH“2 iLOX pump N-2,000 -- x de to 10 ke +2db discharge psia No. 2 CO3h LOX injection 0-3, 000 -o x de to 10 ke +2db psia KFTa-1 Fuel pump 6-200 -- x dc to 10 ke 12db inlet No, f pela PFad-] Fuel pump 0-2, 500 -- 4 de to 10 ke £2db discharge psia No. 1 CFila Fuel mani- 0-2, 000 -~ Xx de to 10 ke +2db told nsia CF2a Fuel injec- 0-2, 000 - x de to 10 ke 22b tion psa CGla Combustion 0-3, 000 oe x de to 10 ke 12db chamber psia GGic Gas generar 0-1, 500 ~~ x de to 10 ke 42db tor chamber psia Sec notes LOX duct ~300" to +1.0 See note. Engine position 1 or 2 is mandatory, inlet -250° F and one of engine positions 3, 4, or temperature Sis mandatory, Other positions are highly dcsirable, Temperature must be measured 90 inches or move above oxidizer in- let flange, me LOX suction 2-200 10,5 K line pressure psia GG2n Turbine in- 0° to 21,0 x Turblac inlet manifold temperature let tempera- 2,500°F is also provided as piimary fligl ¢ ture instrumentation system measure - ment attap TG4a. One of the measurements must he classified as mandatory, and the other classi- fied as highly desirable. TGSb Turbine out- G° to £1.0 x let tempera~ 2,000° F ture Rugine cone 0-46 vde -- x tro! valve Start signal ES RT EE Ae a OA NE A Sr figure 2-17. Static Test Instrumentation Category Requirements (Sheet 8 of 9) TN A) AE Ye NENA TNE EAE A fata Set ENA A-43 Section Identification/ Instrumenta~ tion Tap bt tie, R-3896~ 11 Error (Percent Parametec Calibration of Full Deseription ange Ranee) EA ee iain Time Periad/Action/Notes ENGINE~MONITORED INSTRUMEN'L ATION PARAMETERS (cont) Engine cone 0-40 vde ord trol valve stop signal Redundant shutdown Valve siprial 0-40 vde = Hypercol in~ G-40 ede -o stalled switch Binal No, 2 thrust OK pressure Bwitch prekup signal No. 2 thrust OK pressure switch pickup sipnal No. 3 thrast GH pressure switeh pickup signal U-40 vide “~ 0-40 yde 0-40 vde LOX dnine O~ 1, 590 +10 and #fas gen- pela erator LOX injector purge pressure Grow.d hy- 0” tu tid draulic sup- 200° F sly teuipera- ture UC voltaze 0-41) vde £1.0 oe: T mteaee ehh Xx XK See note. See note, Bee note, x TRS TO © rt A CTI SON er EH EE I yA RPL Figure 2-17. Static Test Instrumentation Category Requirements (Suget 9 of $) Two of three thrust OK pressure switches ure classified as manfia- tory, and the other classified ag hiphly desirable. Two of three thrust OK pressure swilches are classified es manda- tory, and the other classified as highly desirable. Iwo of theee thrust OX pressure Svitches mre classified as manda- tory, aud the other classified as ikghiy desoratle. a area ate ane ANE EL NN Ny A A —— ood R-3896-11 Section Ti EE ET Reet ees 8 NEAR irs epee Ee Peal RR ee ct A A a ARAN OT eS A re HEE Nel METS 7 rere te Redline Values — ET a Sr FN Ot Instrumen- = talion Tap Description Minimum | Maxiniuim Ee ES NY Ne eS A ME s cndanemmndlandmeneamebetmantamnartandannonenaemiinametadbeniabdaiel ENGINE PRE-START Time Period/Action/Notes Pe PA ee Peele NH2a Control system supply 400 psig 1, &00 psig Measurements of engine positions 2 pressure (engine posi- 496 ei Ab) 1.850 psi (b) through 5 may be used as redline tion 1 only) pee cae a backups. Facility-supplicd nydraulic umbilical connection pressure, when corrected for system delta P, is an aeceptable alternate for Us redline purameter, Required anytime hydraulic system is in operation prior to start of LOX %0 loadiag. 1,400psig 1, 800 psig Required from start of LOX loading 2 _(b : _ (pb) to checkout valve engine return posi- 1,450psig’” 1,850 psig tion command, 1,400 psig 1, 600 psig Required from checkout valve engine __(b} _ (b) return position command to engine 1,450psig’”" 1, 650 psig control valve start solenoid enetpized. See notes Turbopump LOX 7. -276° F Temperature is measured at or below inlet temperature LOX. pre-vulve. Required at engine control valve start signal Applicable for engine position 1 or 2 and for engine position 3, 4, or 5, LS1 Turbopump No, 1 0° F -- Required from start of LOX loading hearing tempera~ to engine control valve start signal. ture This parameter may he deleted if turbupump bearing thermostat T3 is used a8 an interlock, Engine Turbopump LOX 60 psig 100 psig Maximum allowable pressure during interface seal purge pres- facility or stage system checkout is sure 125 psig. Regaired from start of admitting fuel or LOX to engine pro- pallant feed system to engine contro] valve start Signal and any Cinie fuel or LOX is iy engine propellant feed system. Common supply system pressure measurement ta o erzines is acceptable, See noies. Turbapump LOX -- See notes. A visual inspection of oxidizer aver- seal leakage board drain line is required with LOX in engine system to verify po liquid leakage exists at engine con- trol vaive start signal. {a) Engines not incorporating MDQ9G change. On engines incorporating MONG change, a stage or facility Instrumentation tap must be utilized to raonitor control system supply pressure. (b) These pressure values are applicable at the engine interface. Oe EE TRS TS TD Stein TS TERI fe Figure 2-18, Static Teast Operating Rediine Instrumentation Requirements (Sheet 1 of 3) ee or ar ee Change No, 11 - 6 May 1971 a-4& Section IT R~3996-11 a Pe CRETE RAE ls TS A RP eC OTS, ; Redline Valucs Instrumen- — tation ‘lap Description Minimum Maximum Time Period/Action/Notes ENGINE PRe-SYART (cont) Engine Turbopump LOX 78.3 psia Required at engine control va. 7e Interface inlet pressure start signal. LOX pre-valves open must be interlocked to make sure that all LOX pre-valves are open at engine 3tart. Minimum turbopump LOX inlet pressure is 75 psia if mvasured at or immediately helow the stage LOX pre~vaive, KF6a~-1 Turbopump fuel 43.3 psia Required at engine control valve inlet pressure Start signal. Fuel pre-valves open No, 1 must be Interlocked to make sure that al! fuel pre-valves are open at engine start, Measurements of en- gine positions 2 through 5 or No. 2 fuel pump inlet pressure imay be used as a backup. Engine Hydraulic supply 60° F 130° F Required from start of LOX load- interface iemperature ing to engine control valve start signal, Common supply system temperature measurement to 5 en- gines is acceptable. Engine DC electrical 24 vie 32 vde Fron initial power application to Interface voltage checkout valve engine return posi- tion command, Common voltage measurement to 5 engines is acceptable, 24 velc 39 vide From checkout valve engine return position command to engine control valve starl signal. 90 Engine LOX dome and gus 120 psig Under flow conditions. From engine Interface generator LOX in- igniter firing signal to engine thrust jector purge pres- OK pressure switch signal at a maxi- sure rum lockup pressure of 1,200 psig. Common supply system measurement to S engines is acceptable. Sequence purge on so that system is primed at igniter firing signal, ENGINE START TO ENGINE SHUTDOWN PF10 Turbopump fuel 150 psig 350 psig Minimurn value is applicable $ impeller back- 400 psig seconds after engine control valve casing pressure Start signal; 400 psig is applicable 0-10 seconds after engine control valve atart elgnal. ne 6 aie er —— - re fi Rete eer re * LIER igure 2-18, Statle Test Operating Rediine Instrumentation Requirements (Sheet 2 of 3) 2-46 Change No. 11 - 6 May 1971 R~3896-11 RR oe Instrumen- tation Tap ~~ Redline Values Description Minimum | Maximum ENGINE START TO aa ENGINE, SHUTDOWN (cont) KF6a-1 Turhbopump fuel 12 psig “= inlet pressure No. 1 PF2a-1 Turbopump fucl -- 2,280 psiv discharge pres- sure No, 1 Engine Turbopuinp LOX 30 psig “- interface inlet PO2a-1 Turbopump LOX “ 1, 700 psig discharpe pres- sure No. 1 POTa Turbopump LOX = 12 psig seal cavily pros- sure LBla Turbopuimp bear- 200 psig 540 psig ing jet pressure ada} Turbine manifold -- 1,775° F temperature Engine LOX puny seal 30 psig 100 psig inter- purge pressure face CZAL0-¥ Vibration safety -- See notes. cutoff CZA4-Y CZAL-¥ coe Le LN LF at ty I YS AO ch PET oct mPa de Figure 2-18. eer ee atin nes Fm a ren et RE Am em pe pene Static Test Operating Redline Instrurmentation Nequirements (Sheet 3 of 3) Section IT Time Period/Action/Notes Rar Het EAA TORE 9 Minimum value is applicable 6 seconds after engine control valve start signal, Other No, lar No 2 turbopump in~- let measurements ave acceptable altornates for the parameter. Other No, 1 or No, 2 turbopump fuel discharge pressure measurements are acceptable allernates for this parameter. Minimum value is applicable 6 seconds after engine control valve start signal, This parameter may be used to limit turbopump speed to 5,800 rpm and may be adjusted to a maximum value of 2,010 psig. Other No. l or No, 2 turbopump LOX discharge pressure meacurements are acceptable alternates for this parameter, Other turbapump LOX seal cavity pressure measurements are accept- able alternates for this parameter, Minimum value is applicable 8 seconds after engine control valve start signal. Other turbopump bearing jet pres- sure measurements are acceplabliv alicrnates for this parameter. Maximum value is applicale from en- eine contrel valve start signal. Tur-~ bine inlet temperature with maxi- mum value of 1,575° F is an accept- able alternate for this parameter, Maximum and rainimum values are ap- plicable from engine control valve start signal. Commion supply system measurement to 5 engines 1s eccept- able. 100g ring for 45 milliseconds continu-~ ously from 2 of 3 accelerometers (ap- plicable frum engine control valve start signal). ee eetdinhemadeea eee 2-47 Section I Identification/ Instrumenta- tion Tap KF6a-1 TG5ec PF2a-2 CGle GGlid POda«2 NH5dc KT eee ee ay EE Sr Parameter Calibration Description Oe eee arte ee, Fuel pump inlet Turbine outlet Fuel pump discharge No, 2 Combustion chamber Gas genera- tor chamber LOX pump discharge No. 2 Common hy- draulie re- turn LOX pump bearing jet LOX pump bearing No, 1 Turbine iniet Gas venera- tor ball valve limit switch Fuel valve No, 1 iimit ewltch Fuel valve No. 1 position Range — 0-200 psia 0-100 psia 0-2, 500 psia Q-1, 500 psia 0-1, 500 psia 0-2, 000 psia 0-500 psia 0-1, 600 psia 0° to 400° F 0° to 2,000" F On- off (open- closed) On- off (open- close) Q- 100% 8 ir ere R- 3896-11 Error (Percent of Full Range) PRIMARY FLIGHT INSTRUMENTATION $2.0 £1.90 +2.0 +2.0 +2.0 +2.0 (a) Engines not incorporating MDLY6 chanze one ae rere 2-46 a ee meen Figure 2-19. ae res ahr POP Launch Instrumentation Category Requirements (Sheet 1 of 3) See notes. x Xx See notes. re One of five engine positions is man- datory unless fuel lank ullage pres- sure measurements are aperational, If fuel tank ullage pressure is oper- ational, these measurements are clessiiied as highly desirable. Measurement may be classified as highly desirable if turbopumnp bear- ing thermostat T3 is used as an interlock. Identification KG is an MSFC num-~ ber reference. Closed position is raandatory, and open position is highly desirable. Identification K7 is an MSFC num- her refcrence, Ce ee ee ny R-3896-11 Section I Error Identilication/ (Percent lustrumenta- Parameter Calibration of Full Calegory tion Tap Description Range Range) M HD Tine Veriod/Action/Notes PRIMARY FLIGHT INSTRUMENTATION (cont) eee KB Fuel valve On-off “- x Identification K8 is an MSFC num- No. 2 limit (open- ber reference. switch closed) Fuel valve 0-100% -- x No, 2 positiun KO Oxidizer On-off -- See nutes. Identification K9 is an MSFC num- valve No, 3 (open- ber reference, limit swite closed ae init switch losed) Closed position is mandatory; open position is highly desirable, Oxidizer 0-100; -- 4 valve No. 1 position K10 Oxidizer On-off -- See notes, Identification K10 is an MSFC num-~ valve No, 2 = {open- ber reference. limit switch — closed) Closed position is mandatory, open position is highly desirable. Oxidizer 0-100% -- Xx valve No. 2 position Tl Turbopump 0-7, U60 -- X [dentification T1 is an MSFC num- rpm No, tL rpm ber reference. RPM No. 1 is an ac cycle count (0-234 cps). Turbopump 0-7, 900 X iPM No, 2 is an ac cycle count rpm No, 2 rpm (0-4, 200 cps). 44 Heat ex- chanrer 1,0% inlet flow: pickup 20-100 22,0 X Identification F44 is an MSEC num- gpin ber reference. CGTL Engine en- 0° ta £20 X Identification CGT1 is an MSFC vironmental 1,500° F number reference temperature 0° to $,000° F(L) AURILIARY FLIGUT INSTRUMENTATION Engines not incorporating MN96 chance. PF2a-1 Fuel pump 0-2, 500 42.0 x diacharge psta No. 1 PORs-1 LOX pump 0-2, 000 42.0 ™ discharge psia No, i (by) Engines Incorporating MD159 change Pee ee “Figire 2-19" Launch tnatriumentation Category Requirements (Sheet 2 of 5) Change No. 7 ~ 28 April 19'70 2-49 Section 0 Identification/ Instrumenta- tion Tap YAR Creme eee A a A SR Ry SP heer er IY a kitror (Percent of Full Parameter Calibration Description Range ee A EE EN OL ENP Bee HOIb HO4a HH2a HU3a Pova Hola HOW tHidhb gha Ki'va-2 “w PZAI“¥ PZA2-¥ PZA3- 7% PZA4-X 2-50 Engine con- trol opening Engine con trol Heat ex- changer LOX inlet Heat ex- changer GOX vuilet Heat ex- changer hee lium. inlet Haat ex- changer he- lium cutlet TO* pump seal cavity Heat ae change LOX’ let Heat ex- changer (OX outlet Hieat ex- changer he- lium outlet Fucl pump inlet aie) 2 LOX pump inlet Mange Fuel pump inlet elbow Fuel purip inlet elbow Fvel pump inlet elbyw a eetaneciedlem thn ee teiesteemmmttone taal Figure 2-19. Launch Instrumentation Category Requixements (Sheet 3 of 5) Q-2, 500 psia 0-2, 500 psia 0-2, 000 psia Q~2, 000 psia 0-500 psia 0-500 psia 0-50 psia ~390% to -250° F -300° to +800 F 300° ty +600° F 0° to 190° F 0-250 4 0-250¢ 0-250¢ f-38D6- 11 sage) 12.0 +2.0 +2.0 +2.0 2,9 Change No. 6 - 10 February 1970 ee Time Perlod/Action/Notes Seated id eer’ AUXILIARY FLIGHT INSTRUMENTA’ TION (cont) x Sev notes, One of five engine positions is man- datory. This measurement may he classified as highly desirable if the facility-supplied hydraulic umbili- cal connection pressure is opera- tional, x ENGINE-MONITORED INSTRUMENTALION PARAMETERS x 0-3, 500 cps filter x )-3, 500 eps filter x Triaxial mounting pad 0-3, 500 eps 4 Triazlal mounting pad 0-3, 500 cps ¢ Error (Percent Identification/ Instrumenta- Parameter tion Tap PZAS- ¥ PZAI- 4 CAAIG- ¥ C4A4- Y CGla GGle See nutes. Ar ee ee I es Description Calibration Rune R-3896- 11 of Full Range) FR eterna eS aN RS TL i i SN eee re M [#0 Category Section II ROWER A te cat RE A Me SD Time Period/Action,/Notes oo EL ETS PP PE ENGINE- MONITORED INSTRUMENTATION PARAMETERS (cont) Fuel puinp housing Fuel pump housing LOX. dome LOX dome Con:hustion chamber Gas penera- tor chamber LOX pump inlet LOX duct inlet temperature LOX suction line pressure Engine con- trol valve atart signa) Engine cone tral valve stop signal Redundant shutdown valve signal Hyperpol instaJied switch Sirnal No. f/ thrust OK pressure switch pick- up signal No. 2 thrust OK pressure switch pickup signal 0-250¢ Q-250¢ 0-707¢ 0-707 G-3, 000 psia O-1, 500 psia 0-200) psia -300° to ~a50’ F 0-200 psia 0-40 vde 0-40 vde 0-40 yvde 0-40 vde 0-40 vde 0-40 vde 1a natrewrername 1 4 4 ~*~ See notes. See notes. See notes, TriaxiaJ mounting pad 0-3, 500 cps 6-3, 800 cps de to 10 ke +2 db de to 10 ke ¢2 dh de tu 10 ke +2 db de to 10 ke +2 db de to 10 ke #2 di Engine position 1 or 2 is mandatory, and one of engine positions 3, 4, or Sis mandatory, Other positions are highly desirable, One of five engine positions is man- datory; others are highly desirable. This measuvernent may be classi- fied as highly desirable if a LOX tank ullage pressure measurement is operational, Two of three thrust OK pressure switches are classified as manda- tory, and the ofher classified as highly desirable. Two of three (hrust OK pressure switcheg are classified as manda- tory, and the other classified as highly desirable. ey etme HAS A me tb ARNE ek sr oe PA PP NE NP rp a AO Figure 2-19. Launch Instrumentation Category Requirements (Sheet 4 of 5) Section I R- 3896-11 Error Identification/ (Percent Instrumenta- Parameter Calibration of Full Time Period/Action/Notes tion Tap oe eription see Range) ENGINE- MONITORED INSTRUMENTATION PARAMETERS (cont) or No. 3thrust 0-40 vde -- See nutes. Twoof three thrust OK pressure OK pressure switches are classified aa manda« switch pick- tory, and the other classified as up signal highly desirable. “- LOX dume 0-1, 500 +1,0 x and gas gen psia erator LOX injector purge = Ground by- 0” ta $1.0 x draulic sup- 200° F ply tempera~ ture -~ BC voltage 0-40 vde t1.0 x Pet ere se remem oe rarer et le re a a any an RN en ener erie mene i ea Figure 2-19. Launch instrumentation Category. Requir ements (Sheet 5 of. 5) ae pe org nr ar oa eee tt Acar ae a ieteuniere “Redline Values tation Tap Description Minimum Maximum Time Perlod/Action/Notes nN a A A rR a ert ei ee mA Petite tir att westerners Baseman nme NH2a®) Control system supply 400 psig 1,800 psig Measurements of engine positions 2 pressure (engine posi- {b) through 5 may be used as redline tion 1 only) backups. A facility-supplied hy- draulic umbilical connection pres- sure, when corrected for system delta P, ig an acceptable alternate for this redline. 415 psig”) 4, 850 psig 7 Required anytime hydraulic cystern is in operation prior to start of LOX loading. 1,400 psig 1,800 psig Required from start of LOX loading , (hb) _, {b) to checkout valve engine return posi- 1,450 psig’ ” 1,850 psig’ tion command. e 1,400 psig 1, 600 psig Required from checkout valve engine ._(b) (pb) return position command to engine 1, 450 psig cantrol valve start solenoid energized. 1,650 psig (a) Engines not incorporating MD96 change. On engines incorporating MD96 change, a stage or facility instrumentation tap must be utilized to monitor control system “supply pressure. (b) Pressure values are applicable at the engine interface, arr et sy NG A STNG — EE farce ~— Figure 2-20, Launch Operating Redline Instrumentation Requirements (Sheet 1 of 3) 2-52 Change No. 11 - 6 May 1971 R- 3806-1) Section Instrumeni- | Redline Values lation Tap Description hence waes | Maximus Time Perlod/Action/Notes See notes. Turbopump LOX 7s ~275°F Temperature is measured at or inlet temperature below LOX pre-valve. Required at engine control valve alart signal, Applicable for engine position tor 2 and for engine position 3, 4, or 5. LS1 Turbopump No, | 0° F 7“ Required frora elart of LOX Joading bearing temperature iv engine control valye start signal, This parameter may be deleted if turbopump bearing thermostat TS is used aS an interlock, Engine Turbopump LOX 0 psip TOV paig Maximum allowable pressure durlag interface seal purge pressure facility or stage system checkout is 125 psig. Required from start of admitting LOX to engine propellant ono feod »yetem and aaytline TOR isin “g engine propellant feed system. Common supply system measure- ment to 5 cpylars is xeceptable, CGT1 Engine environmental 0° F 130° F Measurements of engine pogitton 2, temperature then 1, 3, 4, and 5 may he used as redline alternales, 907 Common supply system temperature measurement, when corrected for system delta fT, to 5 engines is acceptable backup for this redline. See notes. “Turbopuinp LOX =~ See notes. A visual inspection of oxidizer over- seal leakage board drain ling is required with LOX in engine system to verify no Nquid leakage exists at engine con~ trol vaive start signal, gngine Turbopump LOZ, 16,3 psia Required at engine control valve interface inlet pressure start signal, LOX pre-valves open must be interlocked to make sure all LOX pre-valves are open at engine start. If pressure is ineasured at or jmmediately below stage LOX pre- valve, 75 psia is minimum, One of five engine position measure- ments or LOX tank ullage pressure measurement of a minimum value of 23.7 psia is acceptable as redline alternate, fe ee red er remem ees Fipuce 2-20, Launch Operating Redline Instrumentation Requirements (Sheet 2 of 3) Change No. 1k - 6 May 1971-22-53 Section If R-3896-i1 Paragraphs 2.7 to 2.7.1 Redline Values Instrumen- = tation Tap Deseription Minimum | Maximum Time Period/Action/Notes BF6a-~ i Fuel pump inlet pres- 43.3 psia Fuel pre-valves open must be inter- sure Na. 1 (engine locked to make sure all fuel pre- position 1 only) valves are open at engine start, Fuel tank wage minimum pressure redline Ig an acceptable aiternate with 27 psila. Messurernents of en- fine positions 2 through 5 or No. 2 fuel pump intet pressure roay be vsed as redjine backup, Required at engine control valve start signal. knpine Hydraulic supply 60° F 130° F Kequired from start of LOX Joading interface teinperature to engine control valve start signal, Common supply system measure- ment to 5 engines is acceptable. Engine DC electrical -- 32 vde Brom inifial power application to interface voltage checkouf valve engine return position command, Common voltage ineasurement to § engines is acceptable. 24 vie 30 vde From checkout valve engine return position cominand to engine control valve start signal. 7] 720 Engine LOX dome and pag 120 psig From engine igniter firing signal to interface generator LOX engine thrust OK pressure switch injector purge signal ata maximum lockup pres- sure of 1,200 psig. Contraon supply system measurement to 5 engines 18 acceptable. es aT ee at 2 Mt ra A nS Figure 2-20, Launch Operating Redline Instrumentation Requizements (Sheet 3 of 3) er neers a en ll eR A 2.7 APPLICABI E SPECIFICATIONS. MIL-C-10173D Corrosion Preventive Amendment 2 Cumpownd, Solvent 2.¢.1 Throughout this manual reference is 19 November 1968 Cutback, Cold Appli- madn to the following specifications by title vation, Grade I and basic dowument number; however, in all cases the issue specified below shall govern. MIL-C-8130283 Cleaning Compound, ne 24 December 1368 Sulvent Trichlorotri- MIL- B- 131 Barrier Material, Water fluoroethbane Amendment tf Yaporproof, Flexible, {4 July 1967 Hoat Scalable Mile C-~ 142014 Corrosion Preventive, 23 April 1956 Soft Film, Cold Applt- cation 2-54 Change No. 13 - 4 April 1972 MU. F-25558B Amendment 3 14 March 1963 Bod MIL-~L-25567C 9 June 1971 MIL- P-~-25508D ee March 1962 MIL-P-27401B 19 Sapte mber 1962 MIL-P-25876C Amendment 1 3 November 1967 B MSFC-SPEC-217 g 10 August 1962 934 WSEC~STD-500A Amendment 2 26 September 1970 MIL T-276028A 25 January 1965 BY-~F-1421 aa February 1968 g O-T-634b y Amendment 1 #9 October 1968 P-D-~680 Amendment 2 9 June 1964 PPP-T~QN69C gsAmendnent 2 2 Murch 1970 TT-[-T45a Amendment 2 5 May 1964 A VV-L-800A 420 February 1970 Fuel Ramjet Engine, Grade RJ-1 Leak Test Compound Oxygen Systems Propellant, Oxygen R~3896-11 Section iL VV-P-236 17 December 1954 Petrolatum, Technical Helium Bureau of Mines, ; Helium Grade A Propellant Pressuriang Agent, Nitrogen Propellant, Kerosene Trichloroethylene, Technical 5-1 Stage Storage Trichioroethylene, Oxygen Propellant Compatible Fluorocarbon Refrigecants (Type 12) Trichloroetnylene, Technical Dry Cleaning Solvent fape: Pressure- Sensitive «adhesive; Waterproof, For Packaging Isopropyl Alcohol Lubricating Gil, General Purpose, Preservative, (Water-Displacing, Low Temperature) Change No, 18 - 4 April 1972 2-45 /2-56 R-3896-11 Sectloa AI Paragraphs 3,1 to 3,1,2 SECTION OPERATING PROCEDURES WARNING THE FOLLOWING GROUND SUPPORT EQUIPMENT MUST BE OPERATED BY AUTHORIZED PERSONNEL TRAINED IN THE USE OF THE KQUIPMENT, (32080, Oxidizer Donie Flushing Kit G20387, Fuel Drainage Kit G2038, Scavenge Pump G3104. Pnetunatic Flow Tester 3132, Test Plate, Plug, and ‘Tool Set G313, Hypergol System Tool Kit G3136, Thrust Chamber Throat Plug G3142, Engine Checkout Console G3144, Turbine Exhaust Exit Pressure Check Fixture A I Re LE A TN SCOPE, This sectlon contains recommended deta] procedures to perform authorized activi- ties snecified in section J, In fhe event of conflict between criteria specified in sections fT und U and in this section, sections I and IL cri- teria shall apply, Turing the following proce- dures, Stage Contractor and/or NAGA supplied cetailed procedures inust be used when installing interconnects between the engine aud ground support equipment and/or checkout equipment that are not Supplied by the Engine Contractor. When performing work specified in this manual, all loca) safety and health directives must be compliec with. It is assumad these directives ave in conpliance with the Occupational and Safety Healtn Acc. When local safety and health directives a.@ more stringent than those speci- fied in this manual, the local directives will prevail, 3.1 INSPEC‘CIONS. 3,1.1 When no recommendations are made for the method of performing the inspection activi- ties specified in sections T and 11, no additional instructions are required, G3153, High-Voltage Iguiter G4049 or 75M51505, Engine Vertical Installer G4069, Engine Handler G4079, Nozzle Extension Alinement Tool G4089 or 99-9026815, Thrust Chamber Throat Security Closure 9026622, Inert Igniter 99-9012908, Fuel Drain Vent Adapter Kit 3.1,2 VARIABLE ORIFICK INSPECTION, Visually verify that part number and size of each variable orifice installed on the engine agrees, wilhin machining tolerance, with the variable orifice nominal size recorded in the Engine Log Book. The orlfice is identified with the actual measured size, which niay differ from the Engine Log Book Record (numinal size) to the extent ot the tolerances listed as follows: | Part Tolerance Number _Ainch) D251-4071- 10.001 RD251-4072- 10.001 RD251-4080- x0, GOL RD251-4083- 10,901 RD251-4085- 10,001 RD251-4087- 4,001 RD251-4098~ 410,001 RD251-4100- 40.002 RD251-4103- 1.002 RD251-4104- 10. 002 RD251-4108- 0,001 RD251-4118- 40.002 RD251-4129- 40,0005 RN251-4130- +0.0005 RD251-4131- 30.0005 RD251-5001- 40.001 RD2738-1027- +0,0005, -0, 0000 Change No. 14 - 9 October 1972 3-i Section M1 Paragraphs 3,1.3 to 3, 1A,1 3.1.3 OLDEST ASSEMBLY/INSTALLATION DATE IWSPECTION. Verify that date embnsned on metal strip atlached to engine mount strut and marked OLDEST ASSEMBLY/ INSTALLATION DAT agrees with oldst instull date recorded in Engine Log Book on Age Contro\ Log for Component Synthetic Rubber Items form, Jf the dates do not agree, determine accuracy of E:.gine Log Book entry; then, if required, er.boss a new 1/2-inch wide nietal strip of alumiaum, CRES, or zinc with the words (3/32-inch-high letters) OLDEST ASSEMpLY/INSTALLATION DATE followed by the oldest install date recorded in Engine {Log Book and safetywire new metal ctriv in place of ola metal strip with Incanel iockwire MS20895N, 3.14 CONTAMINATION AND DAMAGE PREVENTION, 3.1A.1 When worling with or around the engine, the following procedures should be observed and performed, as applicable, to preclude possible contamination and/or damage to the engine. a. Make sure that clothing worn by personnel is free of loose particles and fibers and pockels are emptied of foreign objects that could con- tribute to contamination, b. Take only reguired parts, tools, and test equipment in engine area; perform an account- Ing of toes and parts at beginning and end of a procedure. c. Make sure that all test equipment and tools used meet the cleanness requirements for use in liquid oxygen, fuel, and pneumatic SYSlcmMsS. d, Make sure that tools are properly tath- ered to carrying individual or are carried in a suitably tethered bag when work is being performed above engine. e. Provide water shields and wind breaks when an engine system is to be opened in an outdoor location during ratn or high winds, 3-2 Change No. 14 - 9 October 1972 R-3896-11 f, Make sure that areas ar. checked above, around, and below system being opened for uperations that may cause or allew contamnina- tion oc: system. Take proper measures to prever.t contamination of other systems from system being opened, WARNING The following procedure uses trichloroethylene, which is a toxic solvent. Inhalation of its vapors or prolonged contact with the liquid can cause serious injury or death. a Compresseci gas must nut be used for drying or cleaning unless effertive chip guarding is used and personal protection equipment is worn, g. Prior to opening any engine system, use a regulated source of low-pressure (ess than 30 § psig) gaseous nitrogen (MIL- P- 27401) or clean, dry air corforming to cleanness and humidity requirements of MIL-P-27401 to blow area free of accumulaied loose contaminants (water, sand, etc); then using a clean, lint-free cloth mois- tened with trichloroethylene (MIL-T- 27602), wipe area free of all visible contaminants, h. Provide a suitable container to catch residual fluids when a system is opened, i. Install protective devices as quickly as possible when a system is opened, to prevent the entry of contaminants, CAUTION losizes having sponge rubber seals must wot be used, since contamination of ccmponent or systeta can result, j. Use protective closures and covers specified in R-3896-4 for opened engine systems and removed-part openings when at all possible, Make sure that protective closures and covers are cleaned as outlined in R-3896-3 prior to installation, Secure protective closures and covers with the required number of fasteners, If fewer than the required number of fasteners are used, adequate protection may not be provided, R-3696-11 k, If protective closures or covers specified in R- 3896-4 are not available, flanged areas may be packaged using method shown In figure 3-Al and as follows: CAUTION When Securing Aclai film or bags to the line with tape, a minimum of 25 percent of the tape width must contact the body of the liue to pre- vent the entry of contaminants, NOTE The tape used in this procedure is pressure-seusilive tape B0195-002 (Rocketdyne), (1) Cover open ends of line with Aclar No. 33C fil (0,002-inch minimum thickness) (Allied Chemical Corp), Wrap film over periphery of Mange and secure film to body of line with tape, (2) Install a bag (0. 004~inch minimum thickness) made from clean plastic sheet and strip (Federal Specification L-P-378, Type II) over Aclar film to completely cover and extend beyond film, Expel air fron, bag, and secure bag to body of Hne with tape, NOTE Clean polyethylene bags (Federal Stock No, 81.05-LC0-6811) or clean polyethylene tubing (Federal Stock No, 8135-782-7460), heat sealed at one end, may be used instead of plastic sheet and strip, All polyethylene material used must be 0,004-inch minimum thicknesa, (3) Attach a certificate of cleanness to taped area, if required, (4) Install a second bag (0.004-ineh minl- mum thickness) made from clean plastic sheet and strip (Federal Specification L-P-378, Lyoe 1) over first bag. Expel air from bag, and secure bag to body of line with tape, Section III en a — TAPE SEAL ACLAN FILM is PLACES) PLUID SYSTEM (ae \amm ss IDENTIFICA FON Cale LADRL re ~ I Pp Ste st i Ac : oft a, (2 LAYEES) ia i dines cha Il elec \ (Ger \— heme aE * CERTIFICATE OF C LEANNESS — NOLYETHYLENE TAPE CIRCUMFERENCE HAG [2 REQD) GEN-74 et emo tee oem ry Figure 3-Al. Alternate Protective Closures for Kagine Lines VOTE Clean polyethylene bags (Federal Stock No, 8105- LCO-6811) or clean polyethylene tubing (Federal Stock No, 8135-782 -7460), heat sealed at one end, may be used instead al plastic shect and strip, All polyethylene material used must be 0, 004-ineh minimum thickness, (5) Guther and tape kag over periphery of flange to prevent flange from cutting through bag, (6) Apply 2 layers of tape over outer bag, Tape must cover surface of Nange and extend over periphery of flange. Secure ends of tape by applying a layer of tape around periphery of flange, (7) Attach a fluid systein identification label to line, if sequired, 1. Package pressure caps, plugs, seals, and miscellaneous small parts helig retained for reinstallation in clean plastic sheet and strip (Federal Specification L-P-578, Type ID. Secure package by beat sealing ur with pressure- sensitive tape RBO195-002 (Rocketdyne), Change No. 14 - 9 October 1972 3-24 i ge ce i EL Section IM Paragraphs 3,1B to 3,2.A1 NOTE Clean polycthylene bags (Federal Stock No. 8106-LC0-6811) or clean polyethylene tubing (Federal Stock No. 8135-782-7480) heat sealed at one end, may be used. All poly- ethylene material used must be 0,004 inch thick, m. The following stundard plug and caps of the appropriate size may also be used to pro-~- fect engine and removed-part openings: (1) Plug AN806-J% in tuhe coupling nuts (2) Plug AN814-XXJ and O-ring MS28775 in threaded parts (3) Cap AN929-XXJ on threaded male fittings WARNING The following procedure uses clean- ing compound (MIL-C-81302), which is volatile, Use ina well-ventilated area since the vapors displace the oxygen in the air, resulting in suffo- cation. The following procedure uses iso- propyl alcohol, which is flammable and must not be used near heat, sparks, or oper flame. inhalation of its vapors or prolonged contact with the liquid can cause serious injury. e Compressed gags must not be vsed for drying or cleaning unless effec- tive chip guarding is used and persona) pratection equipment {8 worn, 3-2B Change No, 14 ~ 9 October 1972 R- 3896-11 n. Before removal of a fluid-system closure, clean exterior surfaces of closure using a clean, hemmed nylon cloth cor a clean brush moistened with unused cleaning compound (MIL.-C-81302) or {sopropy! alcohol (Federal Specification TT-I-735), Dry closure with a regulated source of low-pressure (less than 30 psig) gaseous nitro- gen (MIL-P-27401) or clean, dry air conforming to the cleanness and humidity requirements of MIL-P-27401, o. Package protective closures and covers to be reinstalled on the same system opening in clean plastic sheet and strip (Federal Specifica- tion L.-P-378, Type 0). Seal package with pressure-sensitive tape RB0195-002 (Rocketdyne) or by heat sealing. NOTE Clean polyethylene bags (Federal Stock No. 8105-LC0O-6811) or clean polycthylene tubing (Federal Stock No. 8135-782-7460) heat sealed ut one end, may be used, All poly- ethylene material used must be 0,004 inch thick. $,15.1 See figure 3-A2 for materials required to perform tasks specified in thls manual, PROCEDURES. 3.2,Al Engine Checkout Console G3142 is used for testing uninstalled engines, Panels eon the engine checkout console are identified by reference designation number or by numen- clature, In the procedures, panels will be identified by placing the reference designation number or the nomenclature, as applicable, in parentheses. ee, Tdentification en asemeeee w Aclar No, 33C (Allied Chemteal Corp) Airtex 217, Type II (Eou Corp) BB-F-1241, Type 12 (Federal Specification) Brayco 777 (Bray Ot Co) Bureau of Mines, Grade A C-5A (Felt Products) Ethafoam (Dow Chemical Corp) FS1281 (Dow Chemical Corp) Krytox 143A2 (Du Pont) L-P-378, Type 0 (Federal Specification) MB0210-003 (NR, Space Division) MIL- 8-131 MiL-C-14201, Graile 2 MIL-C-16173, Grade I MII-C~81302 MIL- F-25553 MIL- L- 25567 a ecg vere ee eat ty A Figure 3-A2, Materials Specified in This Manual (Sheet 1 of 3) R~3896--11 Film Tying tape Refrigerant Hydraulic fluid Helium Thread compound Foam Grease Fluorinated oi] Plastic sheet and atrip Trichloroethylene Vapor~proof barrler material Corrosion preventive Corrosion preventative compound Cieaning compound RJ-1 fuel Leak-test compound Al 9 A ST Section III be Pe Use Protecting parts, Tying bags on fuel overboard drain system, Leak testing system joints. Lubricating hot gas seals, Leak testing heat exchanger helium colls and lines, Lubricating hot gas fitting threads, Cushioning thrust chamber nozzle extension on pallet, Yubricating fuel system packings. Lubricating thrust chamber fuel and oxidizer seals, Packaging parts and collecting fuel system overboard drain system fluid. Flughing thrust chamber fuel jacket and LOX dome and flushtug gas generator LOX tnjector, Packaging pyrotechnic igniters, Preserving turbopump bearings, Protecting unpainted stationary surfaces, Cleaning desiccant bags, exterlor of closures before they are removed, f and leak-test compound [rom jotnts, Engine hydraulic system fluld from ground supply. Leak testing joints pressurized with gaseous nitrogen. a ee et re eet re: _ Change No, 13 ~ 4 April 1972 3-2C Section Ol ee a rn, Idenilfication i MIL~P- 25508 f MIL~ P-25576 | MIL- P-27401 i MIL~-T-27602 MSFC~SPEC-217 MS20995N * No number y &-T- 634, Type I (Federal Specification) ¥ P-1-680, Type I | (Federal Specification) PPP-T-60 W (Federal Specification) RBO0140-012 # (Rocketdyne) | RBV195~002 (Rocketdyne) # RBOZ10-003 f (Rocketdyne) a R- 3896-11 CO Name HY a Sh a Liquid oxygea Propellant kerosene Gaseous nitrogen Tricoloroethylene Trichioroethylene Inconel lockwire Aluminum foil tape Trichktoroethylene Drycleaning compound Waterproof tape Lubricant grease Pressure-sensitive tape Trichloroethylene —_—— 3-2D Change No, 13 ~ 4 April 1972 ee Use ae oS Engine oxidizer system fluid, Engine fuel systern fluld, Pressuriaing fluid for leak and funcilon testing engine systems and fluid for engine purge systems, Handeleaning exterior surfaces of engine before opening an engine system, flushing thrust chamber fue} Jacket and LOX dome, and Qushing gas generator LOX injector. Flushing thrust chamber fuel jacket and LOX dome and flushing gas generator LOX injector. Safetywiring fittings with lockwire holes and safetywlring torque gear housing cap. Protecting space between fhrust charaber tubes and exhaust manffold, Flushing thrust chamber fuel jacket and LOX dome and flushing gas generator LOX injector. Cleaning hypergol system test tool and manifold. Packaging pyrotechnic igniters and securing fuel overboard drain system fluid collection bags. Lubricating threads and packings in fuel, oxidizer, hydraulic, and over- board drain systems disconnected during checkout, servicing, and storage. Lubricating teat equipment used during engine testing, Securing Ethafoam on thrust chamber nozzle extension pallet and securing Aclar No. 33C film. Flushing thrust chamber fuel jacket and LOX dome and flushing gas generator LOX injector. eh ae Ot GN Ne a ae Eg Figure 3-A2. Materials Specified in This Manua) (Sheet 2 of 3) R..9896-11 RT tie A ERG A a RS cE AR ee identification rr a RBO210-G16 \Rocketdyne) RBO210-017 (Rocketdyne) RBO295-00* (Rocketdyne) RTV-102 (General Electric fa) SAE 5W TT-1-725 (Federal Specification) VV-L-B00 (Federal Specification) VV-P-236 (Federal Specitication) Wh)..40 (Rocket Chemical Co) $105-L.CO-6811 (Federal Stock No, ) 8135~782-7460 (Federal Stock No.) Name Corrosion preventative Sthylene glycol Desiccant White sealant O1) Isopropyl alcohol Juubrieating oil Petrolatum Preservative Polyethylene bag Polyethylene tubing tr a te NE © Me pee nN Section I re er Use Preserving turbopump bearings anc protecting unpainted stationary surfaces, Thrust chamber fuel Jacket prefill fluid, Packaging pyrotechnic igniter and muintaining engine interior humidity. Sealing area between thrust chamber tubes and external bands, Lubricating turbopump torque gear shaft. Cleaning closures, Protecting unpainted working surfaces, Lubricating thrust chamber tube surface that contacts thrust chamber throat plug and Jubricating overlap area on turbine exhaust exit pressure test fixture, Lubricating turbopump torque gear shalt, Packaging parts and collecting fuel system overboard draln system fluid, Packaging parts and collecting fuel system overboard drain system fuid, (a) Compound has limited shelf life, Refer to age-controlled compounds in R- 3696-3 for uSability test, tn er a re re Figure 3-A2. Materlais Specitfled in This Manual (Sheet 3 of 3) Change No, 13 - 4 April 1972 4-2E Section Hl Paragraph 3, 2.1 rn A Ee TS following paragraphs prepare Engine Checkout Console G3142 and the engine for continuous or individual tests, CAUTION Low-flow pneumatic flowmeters {rotometer type) used in the following procedures are easily damaged by flow surges, All valves, regulators, or other flow control devices in systoms con- tainining these Flowmeters must be actuated very slowly to prevent damage to the flowmeters. a. Verify that console circuit breaker, switches, and lights are in the off or neutra) position, regulators and hand valves are closed, and pressure gages indicate zero, b. Verify interconnection belween consoles, (See figure 3-1.) ce. Verlfy that MISSILE AIR FLOW and LOX CLEAN AIR FLOW flowmeters are calibrated at the pressure at which flows are to be measured. d. Verlfy that facility electrical, pneumatic, and hydraulic sources are applied to consoles. e. Determine tests to be performed; then See figures 3-1 and 3-2, and install required olectcical equipment, NOTE For continuous checkout, all electrical equipment should be installed, ® Electrical cable connector torque need be only fingertight. 3-2F Change No, 13 ~ 4 April 1972 R- 3896-11 f. Move MAIN POWER awitch (148) to ON. The following lights must come on: (1) MAIN POWER ON, +DC GROUNDED (dim), and ~-DC GROUNDED (dim) (1A8) (2) NO, 1 NO THRUST, NO, 2 NO THRUST, and NO, 3 NO THRUST (1A7) (3) GROUND and MANUAL (2A7) (4) CLOSED (2A3) (5) NO, 1 CLOSED and NO, 2 CLOSED (2A2) (6) NO, 1 CLOSED and NO, 2 CLOSED (2A8} g. Press CIRCUIT BREAKER 15 AMPS (2A9). All flowmeter Hghts must come on, h, Slowly open GNg, MSL AIR, L. C. AIR, HELIUM, FREON NO, 1, FREON NO, 2, and HYDRAULIC PRESSURE shutoff valves (MANI- FOLD PRESSURE SHUTOFF VALVE PANEL), The following lights must come on: (1) GN, PRESS ON (2) MISSILE ALR ON (3) LOX CLEAN AIR ON (4) HELIUM PRESS ON (5) NO, 1 FREON PRESS ON (6) NO, 2 FREON PRESS ON (7} HYD PRESS ON (1A7) R-~3896- 11 Section O1 ee rr nN a Fm, CONSOLE NO, 1 os ——— NSOLE N abit § FACHITY } OO exertity | a rested ies OSCILLOGRAPH + ' EVENT ' FACILITY ‘ . ae : : uw ul Heil RECORDER Jj {RECORDER 120/208 VAC =e 1 ae Saee a) aie 3860 CYCLE aWwIP IWP2 gwpet 2WPa aly W-0024131 = 2WP10, 2310 49 -9025132 2WwP oT Jari aemrimmrermmns § | 924199 IW b2 19 ©9024) 91) eevee recs sree ser IWP3 ESN eunmnnn eminem wmens |) -'}(}% JLT 19-9023UL6 19-9079B27 iusee 19-9u23818 mantener 19-902 3619 19-9033820 19-9023826 vemos 1902382) 2WwP4 254 10-G026612 coum, 2WP6 256 19-902962B P : 19-9023823 2verg 2J8 p= & bis g BOS 19-DN25824 PRIMARY INSTRUMFNIATION | re] JUNC LION BOX ! PH CP rr te i ey ty y J % “ C3 mt PP a mees OO (miwimvet@uas PIS8 =P 169 ENGINE INTERFACE PV 37S Fl-i-) ome, Figure 3-1. Engine to Engine Checkout Console Test Setup Cable Diagram Change No, 13 - 4 April 1972 8-2G/3-2H R- 3896-11 Section lit A AA F 2 Re i A SE ERCP ~ TURBOPUMP LOX MLET J8a0 TURBOPT AIP £ UEL INLET- TURBOPUMMP FORK pie T THRUST ON ~ COCOON PE RGF PRESSURE, SWITCH SUPPLY PORT QOX RETURN nec HELIUM HETUAN HELIUM SUPPLY FHRUST CILAMAER fi ivr [K)Me AND ME GAS GENERATOR LON INTEC TOlt Ne TON PUMP wary Se \ PURGE Gabe \ « va \ ‘ \ u ENGINE \ CONTROL VALVE \ TRANSDUCERS P158 AND P160 GIMBAL SYSTEM ENGIKE OUPPLY THRUST CHAMBER JACKET PREFILL GIMBAL ACTUA FOR ENGINE AfOUNT -— GIMBAL SYSTEM ACTUATOR AGT LATOR RETURN RETURN HYDRAULIC GIMBAL SYSTEM--—! RETURN —— GIMBAL ACTUATOR ENGINE MOUNT oe t_ yDRAULIC [ijencines NOT INCORPORATING MD96 CHANGE SUPPLY H Fi-LI-4A | ee tre Se PON PE pee, We ere ence irac Figure 3-2, Engine Connect Points for Testing Change No, 1 - 23 April 1969 3-3 Section I R-3896-11 Paragraphs 3.2.2 to 3.2.2.3 4.2.2 ELECTRICAL TESTS YOR UNIN- Procedure Result STALLED ENGINES, (See figure 3-3 through iP a aS e. Record meter No. 1 HEATER CUR- values of No. 1 and RENT and No. 2 u,2.2,1 Flight Instrumentation System Func- No, 2 heaters. HEATER CURRENT tion Test, Test instrumentation usedtoperfarm meters (2A9) indicate the flight instrumentation system function test 7.5 42.5 amperes; activity fs provided by the Stage Contractor. channel 1 prints heater The tes. activity when complemented by criteria temperature rise, referenced in section II, requires no additional instruct.ons; therefore, no récommendations f, Allow heaters Temperature range fur are provided fox ihe method of accomplishing to cycle 3 times. thermostat plekup and this activity. Record minimum and = drapout must be 65° to inaximum tempera- 180° F, 3.2,2.2 Turbopuinp Heater Function Test, tures for each cycle. a. Verify that engine checkout console is prepared for electrical operation (paragraph 3.2, 1), Procedure Result NOTE b. Move LIGHT and ‘Temperature recorder If ambient temperature Is above 85° AC LINE switches neon light comes on. ; F, the heaters may not cycle. Ther- (2A9) (inside tempera- mostats can be cooled with a spray ture recorder door) to refrigerant, Type 12 (Federal Spec- ON. ification BB-F- 1421) applied in short bursts directly on the thermo- NOTE stat. The temperature recorder requires g. Move MOTOR, Yemperature recorder a 5-minute warmup period. AC UINE, and LIGHT neon light goes off and switches (2A9) to OFF. chart paper stops, ce. Move MOTOR Chart paper moves 30 switch (2A9) (inside inches per hour; chan- h. Move HEATER AC POWER PHASE A, temperature recorder nels 1, 2, and 3 print POWER switch (2A0) AC POWER PHASER, door) to ON. ambient temperature, to OFE. AC POWER PHASEC, and HEATER TEMP CAUTION NORMAL lights (2A9) vo off, In the following procedures, any tline the HEATER OVER TEMPER- 3.2.2.3 Hypergol Installed Switch Function Test. ATURE light comes on and/or the eT a. Verify that engine checkout console is HEATER TEMP NORMAL light goes prepared for electrical operation (paragraph off, this test must be discontinued 3.2.1) and the cause of the indication ee deterniined. aA, Perform, as applicable, contamination and damage prevention procedures outlined in d. Move HEATER AC POWER PHASE A, paragraph 3.1A when performing this test, POWER switch (2A9) = AC POWER PHASE B, b. Remove pin and closure from hypergol to ON. AC POWER PHASE C, manifold eaetedee container inlet por. : and HEATER TEMP NORMAL Lights (2A8) came on, 4-4 Change No. 6~ 10 February 1970 R-3896- 11 Section 1 Paragraph 3. 2.2.4 WARNING g. Remove hypergol system test tool, The following precedure uses dry- WARNING cleaning solvent, which 16 flammable and must not be used near heat, The following procedure uses dary- sparks, or open flame. Inhalation cleaning solvent, whichis flanimible of its vapors or prolonged contact and must not be used near heat, With the liquid can cause Serious sparks, or open flame. Inhalation Injury, of its vapors or prolonged contact with the liquid can unuse serious NOTE injury, h. Clean threads of hypergol manifold car- The method for applying lubricant tridge container inlet port wilh drycleaniny in the following procedure is out~ solvent (Federal Specification P-N-680). i R-3896- 3. lined in R- 3896-3 i, Remove packaging ‘rom hypergol manifold cartridge container inlet port closure, Lubricate (Method L) closure packing with FS1281 rrease (Dow Corning Corp). Install clusure and secure with attaching pin. c. Clean threads of hypergol manifold car- tridge container inlet port with drycleaning solvent (Federal Specification P-D-680), Lu- beicate (Method A) threads with lubricant grease RBO140-012 (Kocketdyne). 3.2.2.4 Checkout Valve ‘timing, Test, a. Verify that enpine checkout console is CAUTION prepared for electrical operation (paragraph 3.2.1), When installing the hypergol system test tool into the hypergol manifold cartridge container inlet port, ex- treme care must be used to prevent aA, Perform, as applicable, contamination and gamayse prevention procedures outlined in paragraph 3.1A when performing this test, damage to the hypergot cartridge 4B. Romoye pressure cap from checkout follower, valve engine return hose drain quick-disconnect, o ‘The threads of the test tool cap must Procedure Result be clean and free of nicks to prevent ralling the thieads of the cap and b. Connect a drain Sume hydraulic fluid r 1 : container inlet port. hose between quick- may drain from check- disconnect on checkout out valve engine return Procedure Kesult valve engine return hose when hose is cun- See are ait! house and facilily ny- nected and wnen valve d. Lubricate HYPERGOL CAR- cngulie drains is cycled. f (Method L.) cap pack- TRIDGE INSTALLED ing with FS§1281 grease hight (2A?) remains c. Turn on facility = Channels 13 and 14 (Dow Corning Corp): off. event recorder and indicate off, and 15 then carefully insert Set speed at D0 inches — and 16 indicate on. hypergol system test per minute, Disregard other chan- tool 9021279 into hy- nels. pergol manifold car- CAUTION tcidge container inlet port, and screw cap (clockwise) onto inlet port until cap bottoms, During the following sleps, ground hydraulic pressure must not be ap- plied to engine during checkout valve cycling to preclude introduc- e. Depress and HYPERGOL CAR- ing hydraulic fluid into the fuel hold lever of test TRIDGE INSTALLED feed system. tool. light (2A7) comes on. d. Lift guard, move ENGINE light (2A’7) f. Release lever, HYPERGOL CAR- GRD CHECKOUT switch coues on andGROUND RIDGE INSTALLED (27) lo ENGINE, and light goes off; channels light (2A7) goes off. hold until valve reaches 13 and 14 indicate on and ‘ full travel. 15 and 16 indicate off. Change No, 8 - 9 September 1970 3-5 * bal ale R-3896-11 t 4 t 4 7 i » t Section If “ «t WAG Sere wat. "wv ed at Te mm wee ( ore vue tel - Ne ag ee ~ ” (arrnele eg ee ess eg 5 €¢ @ a Se rromrerens we ~ “ it oe ~ ne 4 “a > mw = ~ ee — 3 te se '* a . “ eee re Cane ee 2 ey f 1 *. ~~ * bao ~~ a _ — a — a te ran ua a * Sane roy “ roe ~ a 2? I fey 1 1 t- re + * m= o ‘ iad Sia — ~~ ~ - sj ~ ze he s Ra en SaenE sot eee = e Sy Fe Pt z Dh he Gee ee ee ee SONA ge” se we wee FM, on Schematic (Sheet 1 of 2) 1 a ¢ LaF Say Olen fees OP at! cet eo MfeaT eo ya tet ann Primary Flight Instrumentat e No. 1 - 23 April 1969 eee Cte Ty 4 Uy SteN 4 I Chang td ENGINES INC ORPORATING MDIS9 CHANGE ere yh wt ed arr ‘a a eeenal 3-6 R-3896-11 Section ILE t rae 4 i ww et € DE au a7 7 5 =r = ddd aly Ble b mae n — ee ge ut 4° : a { i ad 4 wy atic bettas re Pid 73 ——— | eat Op OORATRE ESR ae | | teo0s - , I i jf a ere er ne rot} AaTUayre dL sere: GA pM. bn ¢ =T 4 I es a COE NS Erle te Ty! { ters | far.d | Gib AD ynie Pw Serpe F ye “E OTs Tye eB Leb antes Frat hye Mio ce 1Ot MET HG | er8 HOLA. ssi ike € 02500 ere SS eee ry, rc ee ee ee SQ Cee, ee ee eae ~ = t ey I ese | it | iste tia | jem fragt | yea pene { [eoras ‘ tot . tgacbehy ety Sp oY gor s cl Bay Bhs mame pai as “9 '@ LAGINE $ Yo daerea , taarne wee INC ORTMORATING y at feats ag MVS CInA Gd 4 16 amd a teas 4 os s -é edd Ou Nato NOT La Va ALAS DL Te ENG Body CONSE TAL PEAY OR 46 meee Time OF INC OM PORATENG aS Ende OF fe Age w MDUG CHANGE veer Kayore a a Vii 2a Figure 3-3, Primary flight Instrumentation Schematic (Sheet 2 of 2) Procedure Result Procedure Result e, Release GRD CHECKOUT switch (2A7) (GROUND). f. Measure and record valve travel time from ground position dropout (channel 16) to en- gine position pickup (channel 14) and from engine position dropout (channel 14) to ground position pickup (channel 16). GROUND light (2A7) comes on and ENGINE light goes off; chan- nels 13 and 14 indicate off and 15 and 16 ineli- cate on. Travel time must be 0.5 to 3. 5 seconds for each cycle. g Repeat steps d through f£ 2 additional times. h. Turn facility event recorder off, i. Remove drain hose j. AS specified in steps d through ¢. Recorder stups. connected in step b. Remove pressure cap from pre kaging, and J install pressure cap on checkout valve engine return hose quick-disconnect. Torque pressure cap to 30-40 ft-lb, Safetywire pressure cap with Inconel lockwire MS20995N. Change No, §- 10 February 1970 3-7 Section IN R~-3896-11 aS a LT TY LY A LS RS 1 Pe Pee “Leh me C4 Tisis Fe i faite ea ae Se penne nts : moths ian nana eee ee oe ind: Pe eg - Fou ——— 4 omnes Le seat mF 8D,” + : Ba y Pages rats : ! A af ly saben anata ae G-fomr re (ET To ae nia - db beefy Ty dst i { | Fided aii | i | il | , ot | jk | ek Ake = rie ioe ee ee | Je é : ie of SS Oe a da oo is fs i fl AE TATA Dy vty f & & f r4- bi 60 a my eee if eat P33 a ee EE eas es: TOT 1 aed Col. rece Mae Logo reap | tt { ero rag | eae lo ec roas rie | ies TOL Tere [oe TRAN CUCL | ot | That DALE ee | PEWS Mek ie | Teentou ee? Ly, TM eee is est Ps Ete ceil ee peel Stes Cie a ALE ROVE (WSOPE OS NEL RC COR Me EE OUCH Ike Cri oT OR dg BR te RES RAL COSY DLN ly BRE USLO! O OSD PERS mE O BOER Ty thy PME AS he PSOO CaHTY EE, SURRY D fia ae ria £fe Pots Mi & riers PS 4 Ly P, a r pace eta be ye, iz vas a Ms ey x bes. \ oO per eias ap aie aoe Ble gty YS a . en AT OY ot | i . 4 1 t —aae > =. kos ee is Vit ~~, iN ws | es ¥ » t ~——t eae ~ a8 Tae ~—o4 ~§ i a ™ * s — <5 i a : = ; & t Te 1 he ‘ ——— —. 4 ON oie eccrine =a oi —h> i % S a 2 edge t 2 ‘ ee a4 4 a 2 s chide dood hg S ~4 ab ie Aesth ate dad 4 | iy j i | q | i { [3 12 | { wh duchy teh det tobias J dsl, 43 ad cbs YP Oey? yo dz! Pe mg) et, p Sedge alee < Hy i b deudke bo {CLA FOP A Cuyce? {8 £ 4 od Meras -& F F-4 Ff bu" J wet H pcepel . SED f Bat OC Tope ree pda OL 10 ik Tee | oe | x iO OF PT Had h? nay ThinttnkeR ly, ] Tar aaces ter HAY fork am ; af i A - wat FERS OER bee ed BEATE SCA ee ale EM PA a7 Fret ERY De MPAT Ltrs OO ET LESS REY BEC MEL ROLE REC MI QFE RMR ee EL OD LOE LET E2000 Pye Pid asa nye be JiSE se foe ot 1 |. 45 lew sje d; i 3 ~ MEAP ESL ACER (OT Har ee tat INAED GO Ostet tone NEAT ELMAN ER OT TUR OUTLET FUEL Puts we SAD KO hye F Gore : : i 13] | Rice! (AS el CoE aed ate sas : 3 f"-6 6 frye = B74 Tye usr - ¢ @ & = eye? rd A = }PEs ! 7) serrit kyo ay be? of erty y arrest | nA as Z TS | Pa eth rd ahead y Vea & t { | ce 2 hi fash = iO" TOTO Oakes FI IL 7A Figure 3-4, Audlary Flight Instrumentation Schematic (Engines Not Incorporating MD96 Change) 3-8 Change No. 6 - 10 February 1970 HHS Td i500w JA70 J47 P47 ne mar OS 1 F ot INSTALLED INSTALILEN HYPERGOT CARTRIEX 2 INSTAT LED SWITCH a AAs REPURDANT SHUT DOWN VALVE Figure 3-6, F R- 3896-11 Section Ill P1268 ( Gnd Ji2e[ CBA H OR MM 450 GROL ND PETURN CULCKQUT VALVE oem. Electrical Control Schematic Change No, 1 + 23 April 1969 J450 NODE RETURN Fl-11-5 3-9 Section II R- 3896-11 Paragraphs 3.2.3 to 3.2.3.2 3.2.3 LEAK AND FUNCTION TEST PROCE- DURES FOR UNINSTAILLED ENGINES. (See figures 3-1 through 3-8.) 3.2.3.1 Turbopump Torque Test. a. Remove cap on torque-year housing. b. Attach a turque wrench with an adapter (1-1/16 inch deep socket) and an extension (2 feet Jong) lo torque-pinion-gear shaft. Procedure c. Depress tockpin on tarque-gear housing, and depress torque- pinion- gear by applying pressure to adapter. d, Using torque wrench, slowly rotate turbopump shaft clock- wise and counterclock- wise one full revolu- tion minimum. Record maximum turbopump Shaft breakaway and running torque value, Result Torque- pinion- gear fhaft eigages turbo- pump shaft. Moving elements must not rub, bind, scuff, or register an uneven terque. Torque must not exceed 20 ft-lb. NOTE One revolution of the turbopump shaft requires 5 revolutions of the turbo- pump terque gear. @ Lubrication of che turbopump torque- gear shaft with preservative WD-40 (Rocket Chemical Co) or oil (SAE 4 weight) may reduce binding, rub- bing, and scuffing noise or uneven torque of the turbopurnp torque gear. Refer lo R-3896-3 for pro- cedure on preservative application. €. Remove torque wrench, extension, and adapter. f. Verify that lockpin on torque- fear housing is fully extended and that torque- pinion-gear shaft is in lockout position. 3-10 Change No, 8 - 9 September 1970 NOTE The method for applying lubricant in the following procedure is outlined in R- 3896-3. g- lubricate (Method J) packing with lubri- cant grease R0140-012 Giecketdyue); then install packing on torque: gear housing cap. h. Lubricate (Method A) threads of torque- gear housing cap with lubricant grease RBO140-912 (Rocketdyne): then install vap fingertight on torque-gear house, Safetywire cap with Inconel lurkwire MS10995N, 3.2.3.2 Thrust OK Pressure Switches Leak and Function Test, a. Verify that engine checkout console is prepared for electrical and pneumatic operation (paragraph 3.2.1), aA, Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3,1A when performing this test. b. Verify that NO. 1 NO THRUST, NO, 2 NO THRUST, and NO. 3 NO THRUST pressure swiich-lights (1A7) are on. bA. Remove plastic cap from pressure switch checkout connection at engine interface, Retain plastic cap for reinstallation, NOTE The method for applying lubricant in the following proceduve is outlined in R-3896-3, c. Lubricate (Method A) threads of pressure switch checkout connection with lubricant grease RBO1[40-012 (Rocketdyne); then install pressure Switches adapter 9025291, or equivalent, on pressure switch checkout connection at interface panel, Torque adapter hose coupling nut to 135-185 in-lb, d. Connect fuel hose between adapter and FUEL B.S, TINE port (2A3), e. Position F/M SEL valve (2A3) to BY- PASS, At RE SE a me Cente sane A A CHFCROU] VALVE FO RNGIND, RE EURN HOSE = ~ ACTUATOR SE TO ee eT Ee Ce SO SS SS'NO.'2 OXUIZER HIGH-PRESSURE DUCT Ww = I PEO SLAs SAS SAA ARSED LSSUNS GSS BLUE SEA LA EE RELL f ? NO, 2 FUEL INLET ELBOW G7 Z ALL ELAL ERDAS RLM, Ci *. Shoe MAS r ANS , SENS NO. 1A Wy, LAS CGT LILES, TURBOPUMP CD BEE EO A EEE PL * CHECKOUT a VALVE TNGINI CONTROL “, LL. A ‘FUEL LINE BLEED HOSE UVTI LOLTIETPSETTSTPLIPRY, NO. 2 FUEL HIGH-PRESSURE wag LLELMELEELL EL C072. START prar SOLENGLD CO: SS SHYDRAULIC oe CRETELERESTEAULEL ES SALAS OU CET LIT, es = OUT cit 2 i w . brits fhe sd hn AS ait GENERATON = ae: Le) oe HEAT sores, ae lexciiancer eae: | rae Re. WA (4,0, LL ENGINE CONTROL Ww) iq jp biS 2a on mee Saccocgin _". VALVE SUPPLY TURF —--> cialece 4 RUCEREARECLEAL TCE) FECTRERUREA LAS LEAT SASALE FECT SAL EEA] eae LEFT PLIO O7 rt Ge PP EFESIS ESN WYDRAM AL GROUND SUPPLY HO.” RAD WEDENDANI SHO TOA VA VE ~—-— . pesdunsudesadscsawesniecssissaaeceserseiseq ne cae tee SSSSTEREURLE CRS WO SLE CMET PEEEP LEK! Lh aS ee ~ L MANIFOLD IGNITION MONITOR VALVE - (Mv) one Al the HY TPRGOL MANIFOID OUGUL HOS fae ee terse rary lire , SRE re IMY al NSE { erie | runt bd of pee om oe oh ae ( / {% KROCSASLURURTARCHANIECL OG CMASSENTLER VOLE RAR RAL E EAL ARSE EMAC LE EY vine A735 OPEN it 2 EL EILLT We cR RCP Rae reeser reer err tse Le Ls SATECETs” 7 yt Pre temrapetasadctaausthiaevats cess sii i ee taka aare { < 5 NG ————- ee ee om ee we »—oee ne sat ee Ei err wey Oo f fr a ’ , a oy ‘ ON ca I ces is ec fet CEG hanes nao s

a ee A te a Re ot a ee ee one nn I aa ae HEAT EXCHANGER CHECK VALVE Uy y \ qf PREFIIA A i ~ «18 Gp AH INERT PREFIL aaa t I] | ae CHECK VALVE yes 8 = | J yy “Yak open g 4 i ec [oe eB Pe dt he , t - }) 7H CLOSE OPEK ~s-— A eeneee ae Reereurnesetic ere Re | Sc ial Q CLOSE | foe f LP PE ROOD ECEL VADVE ae: \ extzeccaeer a ot a OLLI URGE PAPER ARLE ARETE P LILES FRE PEESEALEI LEED PL EDLA PEPE PER EES THAR CT TRAEL PER ee ee ie NO 1 OX ER VAI VE ‘THRUST CHAMIER ee — : Ay | FE LE OA L cmmmninnemnittiommnmnntertaldiamsceatetteat Lint wr Figure 3-6, Fluid Contral Sehematic Change No. b- 23 April 1969 3-11 Section II R-- 4896-11 rn ere a eo THROAT CHAMBEE LOX PUM SEAL iO’ DOME AND BULGE GAS GENETIATOR LON INTEC UB PURGE CHECKOD GT VALVE CARY EEE oes BRGINE RETURN AE NO, 2 STE eLTI EL Fre { | HOSE DRAIN A ae (aan rar sy — TD a CS OR DLEMH ELKAEPRADET TTI TET EEE y NO. 2 FURL INLET ELBOW DHAIN —~ (Magner rasa CONTINUOUS" |] ye) ome td i em peage oor| FLOW ‘or onl aeienold areca ae ons: aj teaanee Wd Steuer Woah mene a ae Aaa danne nas Senna a oy Enaeae ee awe F . 3 eas ax) brass Pad GAS af BALL VALVE ACTUATOR FUEL SEAL VENT ~~ ox opp y GENERATOR y, CHECKOUT 4] alin SY EARS OXIDIZER et VALVE 4 : o == ; GE . Vj FESO TP KAA THF ELI LT ETAT PEER IL EET TELE LER tT t BURGE, Sr 4 BALL VALVE PUELINGET Lit INS — DHE CART i it at - ley ACTUATOR [i Stews Marea VW oe aoa r i Aft 2 —* RETURN LINE fi : | | i! eoOx ; [ fey : : f ita a igs og pe a = = ee iT or : ; ss * | C i WYDRAULIC FILTER 7] — Tp ne |’ “Ur i AND FOUR-WAY [BALL qtiapine i y i! SOLENOID VALVE | VALVE NW N t, b= VENT ‘. . MANIFOLD i SHAYT he i. s ! (ENGINE OAIDIZER Le means caneoe ty * ¢ ORENATELLL AE ELLE ERE OL pablich ace SEAL VENT - I i l # y CONTROL BEAL VEN: ; | in ee i ENGINE CONTROL | “YAN : ‘ BALL VALVE } 4H 4 VALVE SUPPLY ©. . VALVE | SHAPT FUEL Si lt , An) | TUBE oa —, SEAL VENT ¥ , 4 9 “ o> GAS GLNELLA LOK ayn " a aa? “ on ne ACTUATOR HOUSING 4 , y no4 ft -mgen « Tones he VENT VALVE - - rE PLT LORTPEL ILS TOP TERE PEE EET TT LA acer ieneeaoees OKO TIO FF CLE REMI LAAT ATARET IIS PTET | a 1 g ut I AeCtre CeUCUCEUECCNTECETUCeTET CTC CTCCrCCeCCn ANSON Os SAN a SNESAAES pile) aol abba aE DS | hee NSS SSS AM BRAS LENSER BSAA CEASA TES OY PNTESAS LASSEN AST VOSA SER UR SR BEAE TENE AS OS g ; an i! | 2Ects =] | ~~ -IGNITION MONTI OR VALVE DRAIN i N ? ? i! { ofa ive TT OA PE TATA TORT OEEIEL SE es fo | a | x ¥ 4 (hea aae = a os afr oh i vi] ¥ , wa Gu wa can ae see SLT Mae Gn aaah eas wine Se ea ar foe, eek oe eer ae ee a ae se ee Sa ep t : : ¥ tf cea hf are 1 onan ) « | Ot X ae oN brad quae ‘ rb y HYPERGOL MANIFO é ; oN RE TL DAM F { eee 1} i N ff _— hi :] SHETROWN 9 { gfe we rood VALS 4 anf i ; x 4 4 awe 4 fA etre 4 to8 " a es) MAY PERGOL Pog y MANIFOLD ; os : 5 DRAIN H S peeuayzrvesare eae ones gh dides Eevee biel eeaie ‘ 4 N ¢ ¢ KYPERGOL “PORGE 2A PURGE { $ i MANIFOLD PURGE 28 Ape mS NO. 2 ‘ | | PURGE 2 a PURGE, | “eas MAIN et delay A Ae ee ate cot dieu ei atieen Se he ee a at te ode Loft th ok Cte ZU DOME | ie "| OXIDIZER 7 2 PING! CHIOR 4 es aa ais = Sage weer Tee een Om meme eee mae te ttre meme a ne ree lease VALINE nee vi 7 ~~ OTHRUSE ru pl ¢ ! MER NO. 2rvEL e, CHAM AE Est FM 2p y) cictt ] HIGH-PREssuRE POME se . . sere ne d moo yet RAIN ‘ ac pees ere. 5. es \ 4 iloluap ir NO, 3 MURGE (POHT 1) ir r Y “yo. 2 Viti Secor ee ide, Se ot, ee ENG PURGE ’ Mefntons? / MAIN care ae Pe oe FUEI, . eke "Soe er & dome porn Ble ip | : ~ SEAT, DRAIN 4 ere ee ia ‘| , SEAL DRAIN mae (PORT §) FURL, INLET MANIFOLD + 2 rut (PORT 2) INDICATOR NO, 2 DRAM ia f DRAIN } f ‘faust CHAMBFR ot FUEL, OVERBOARD if \. | DRAIN — a = pamanerd” desnatgt a rae eatedew modu eft masses mane masts anaa aust annem e ens a e D eden een ant” Extent onset tees eee eat fomne meena a a ee eae Leer te I Ee TS WS a re \ , ; li. ee as 5 [T] excives weoRPUnA TING M145 CHANGE SEE pee at a ea inane i) Figure 3-7. Fluid Purge and Drain Schematic d+ i2 Change No. 1 - 23 April 1969 ay EE TYS fe EP APES fa YSERA he 8] paren wh nag am SC as PUMI SEAL Me —~ PRIMARY OXIDIZER SEAL. Bt Sheena ad MANIFOLD ARS trellyrenarrarey? Aas | , : ( RL LE ERAT FAS ee Sa Sag = Cae El eee ae a de ee ee EN eee, PRESERVATIVE ; 1 eee é Rice iMI a ‘ : 1 BP os: r ees TURBINE BEARING as x , LUBE DRAIN HEARING : co, ae == BALL VALVE LUBE DALAIN SHAFT FUEL : SEAL VENT PURGE CHECK v ; } LEXERALOR | VALE f k NITROGEN PURGE A ATOR HOUSING | S _ OVERBOARD DRAIN 'O} tN VAt Mie oo re ears <_< een SRNBSASNS SER VASSSEN VALLES VST AG RSAN SEN ANS UR ERS AD LSAS SESE ALLE ASE SAASNERS A FO TX EE SFP LL TRE IP RIKER AEE PE SEE LF Lakh et + SAC SUAS OS SE CRC RR ELSES ERROR ERE SEER RAS OG SVANTUNVSANY SSSA V ANTS Bs te BUNSNL CE SERR BUREN SSAA ASA ER EUAN ER TER SALT SUES TREN ESTOS SY a N -—-IGNITION MON'TOR VALVE DRAIN aaa 8 e CF RPAROL EP AA EET EAE L EER us ny wp XS k es 4 ae mm gone ag ee a ee ~ teitere ree o et tee ee esa Ny ia] Sr Se ae ee ee ee eS ee 2 u : pcaaen : s 7OL MANIT OUD \ | { 5 4 ‘ K ‘j 5 doe ek N Ny “. & f x GoIbIZR ie DOME & er \e rarer eberie i PLPGE CHECK ‘ — “HY PERGOL LAINE — R 2 MASIFOLD torn t DRAIN 8 # ERE EET EP ROAD EET EEE LEER EET EOTETETOLIQ EEL EST TT LEE TPELITEIIELEELEES | 4 PERGOT i te RGM, 5 PURGE 28 PURGE IB 4 a ba ] BS Hen PURGE 2B fp iA ‘ 4 4 NO. 1 Ns ee NY Wee pee hat Reta Seder oth NG tan lata pik os tI ae 4. at ae 2 aera fl eae iter a oxmizen °° & — Pee ay 7 ; Coir Ae asad ath a ANS em Act beatae gy tte | TMRUST rans nec ee ge = ee cH § an y NO, 1 FUEL oe y * ACTUATOR ; AMER 4 ‘ . & ee! 4 “ROD N f HIGH-PRESSURE 4 : t 2 FORE 7 fone ie a -- < SEAL VENT Y : 5 DUCT DRAIN eect | — (wont Li | fo ie 8 ' { INDICATOR bets ae ol / : NO. 3 PURGE 5 Than J -- DRAIN , 7 ONO, 4 PURGE : RH aac, Oo ik 7 NO. 1 % . ! pee 7 hi Na CTU STOR it . ~ are ee em ¥ = ra VALVE Cravevree SP are eee ee | SEAL DRAIN i if bs a t Pests (PORT N) : g | I ~— PURGE FOLD \ JFUEL INLEL ManivoLp § i NO. | DRAIN \ x ; Sh AFT A THRUST CHAMBER N Shiusan ene eat SFAL DRAIN rein EMVGAR S tats sont) _ SSE ge rratte spear pares ae ATS an TS ee a, Te TE TE TR Na, pg Cerise ieee SIT SISTA of ; ae \ LEGEND * ra GN, PURGE \ T7779 FUEL OVERBOARD DUAIN wi Conia ane KaST5H1 LOX OVERBOARD DRAIN eee DRALH ADAVERRS (TYP 4 PLACES) trang NITROGEN OVERBOATIID DRAIN ith RA OT A A SAAT tl SR SA ER ey RAVE or ntartinn | TT Rh ye AEB tre ——— BEARING LUBE NO. 2 DRAIN Porter Tarn HEARING 1 UBE NO, | DRAIN FS TET CERES PE kl eS Seed} Grieg cae Pesecrai is Bh Tals RS TBA, serra FUEL DRAIN PII IART ERI Pree re ee _ Se | feb PRIMARY FUEL. le al SEAL MO, 1 DRAIN { = FUEL {l o--- _~ Pied ear INLET sheeedy. PP e read cata SFAL, on | i Tein tosis i NO, 2 | | | A p BRAN | -—ko i * f ; peat and pas gen- : ate adele Or adapiee ane dae een IMV CONT PRESS NO. 2 CLOSED lights erator ball valve fuel housing ¢ an spl Ne fF se veaiit-in-eeal Teakare REG (2A7}. Monilor (2A6) go off. NO. 1 eg ce ee and record IMV CON- OPEN and NO. ZOVEN (3) Gas gronerator ball valve fuel inlet TROL PRESS LOW lights (2A6) come on. drain ya ¢ pressure when Shuttle pressure must ‘ i , y ‘ esigr (4) Turbopuimp No, 1 feel inlet elbow drain Nr 1 and No.2 fuck be 20 24 psig. valves open, fd THs gat uw jr n “ay (6) Turboptnm No. 2 fuel inJet elbow drain j. Move FOUR- NO. J OPEN and NO. 2 dc, After completion of drainay > from hoses WAY VALVE switch OPEN (2A2), gas sren- installed in step dA, remove drain hoses, ex- (1A1) ta STOP, eratus OPEN (243), cept for No, ft fwel high-presaur duet drain on and NO, LOTEN and engines with gimLal actuators installed, ftemove NO 2 OPEN (246) pressure caps from packaging, and install pres- Nehts gooff. KO. 1 sure caps, execpt for fas generator ball valve CLOSED and NO. 2 fuel inial drain, on each quick-disconnect. CLOSED (242), :aa Torque 3,'8-inch pressure caps lo 30-40 fi-Ib generator CLOSE (243), and 3/3-inch pressure caps to 10-75 ft-ib, and NO. 1 CLOSED and NO, 2 CLOSED (2A6) Hights come on. 3-26 Change No. 8 - 9 September 1970 R- 3896-11 Procedure k, Close IMY CONT PRESS REG (2A7). Gpen IMV CONTROL BLEED valve until MV CON- TROL PRESS LOW gape indicates zero, Close valve. 1. Repeat steps h throush k 2 addi- tional times. Result, CONTROL port is de- pressurized, Tenifion monitor valve shuttle pressures re- corded in the 3 tests must be within 2 psig of cach other. JA. Close HYD Hl- FLOW SHUTOFF valve (142). CAUTION The HYD HI- FLOW SHUTOFF valve must be completely closed befure closing the HYD HI- FLOW REG, to prevent damage lo pressure reducing valve 19-9023747. m. Close HYD HI- FLOW REG (142) until HY Hl- + LOW PRESS rare indicates zero, Engine hydraulic con- trol system is depres- surised. 3.2.3.10 Fpni tion Monitor Valve Interflow Test, a. Verify that engine checkout console is pre- pared for electrical, pneumatic. and hydraulic operation (paragraph 3,2,1), aA. Perform, as appheable, contamination and damage prevention procedures outlined in paragraph 3,1A when performing this test, b. Remove pin and closure from hypergol manifold cartridge container inlet port, WARNING The following procedure uses dry- cleaning selyent, which 13 flammable aud must not be used near heat, sparks, or open ame, Inhalation of its vapors ur prolonged contact with the liquid fan cause serous injury. NOTE The method for applying lubrieant in the fullowing procedure is outlined in R-~3896-3, e, Clean threads of hypergol manifold car- tridge coniainer inlet port with drycleaning satyout (iederal Specification P-D-680), Lubri- cate (Method A) theeads with lubricant wrease RBOUI40-912 (Rockcfdyne), section Ik Paragraph 3.2.3, 10 CAUTION When installing the hypergot system test tool into the hypergol manifold cartridge container inlet port, ex- treme care inust be used to prevent damage to the hypergol cartridze follower, The threads of the test tool cap must bo clean and free of nicks to prevent galling the Lbreads of the eap and in- let port. Procedure Result HYPERGOL CAR- TRIDGE INSTALLED light (2A7) remains off, d. Make sure that throuds of test tool cap are clean and free of nicks; then lubricate (Method I.) cap pack- ing with F$128] vrease (Dow Corning Corp) and carefully imgexrt hyperzol system test tool 9021279 inty hy - pergo) maaifold car- trickre container inlet port. Serew cap {clockwise) outo inlet port until it boltems. dA. Verify that drain hoses are installed on engine contro, valve supply tube drain and check- out valve engine return hose drain (paray raph 3.2.3.8), dB. Remove pressure cap from, and attacha drain hose to, tue following quick-disconnects: (1) No. 1 fuel high-pressure duct drain (2) No. 2 fuel high-pressure duct drain CAUTION Tn the following procedure, during: re- moval of the gas generator ball vaive fuel inlet quick-disconnect cap, the quick- disconnect body must not be allowed to turn since a torque de- crease between quick-cisconnect body and adapler or adapter and gas gen- erator ball vatve fuel houstiy ean result in seal leakage. (3) Cas pencralor ball valve fuel inlet drain (4} Turbopump No. \ fuel inlet elhow drain (5) ‘Turbonump No. 2 fuel ielet elbow drain Chenge No. 8 - 9 September 1970 3-271 Section II dc, After contpletion of drainage from hoses installed in step JA, remove drain hoses, ex- cept for No. 1 fuel high-pressure duct drain on engines with gimbal actuators installed. Remove pressure caps from packaging, and install pres sure caps, except fur gas generator ball valve fuel inlet drain, on each quick-disconnect, Torque 3/8-inch pressure caps to 30-40 ft-lb and 3/4-inch pressure caps to 70-75 ft-tb, NOTE The methea for applying lubricant in the follow.ng procedure is outlined in R-3896-3. dp, Lubricate (Method A)threads of gas gen- erator ball valve fuel tnlet drain guick -disconnect with lubricant grease RBO110-012 (Rocketdyne) or 51281 peease (Dow Corning Corp), ard in- stall pressure cap. Torque pressure cap to 210-240 in-lb, d¥, Satetywire al) quick-disconnect pressure caps with Inconel lockwire MS20995N, e, Verify that hydeaulic system is connected to engine {paragraph 3. 2.3.8). f. Verify that pressure test fixture is in- éCailed Letween ignition monitor valve geuse tube flange and thrust cham c fuel inlet flange (paragraph 3.2, 3.9). g. Verify that a pneumatic hose is installed between ignitlon monitor valve CONTROL port and IMV CONT PORT (2A7) (paragraph 3.2.3.8). Result, HYPERGOL CAR- TRIDGE INSTALLED light (247) comes on. hA. Open HYD HI--FLOW SHUTOF valve (1A2). Proceduie h. Depress and hold lever of test tool. R- 3896-11 CAUTION The following procedure pressurizes the ignition monitor valye CONTROI. port. Wilh the HYPERGOL CAR- TRIDGE INSTALLED light on, pres- sure in excess of tO0 psig must not be applied to the ignition monitor valve CONTROL, port or damage to the ignition monitor valve bolt can result, Proccdure Result, k. SlowlyopenIMV CONTROL port is CONT PRESS REG pressurized. (2A7) until IMV CON- TROL PRESS LOW gage indicates 28 +2 psi. 1. Wait 5 minutes, then verify that No. 1 and No. 2 valves re- main closed. Record rvesuita. m. Move FOUR- WAY VALVE switch {GAl) to SLOP. n. Close IMV CONT PRESS hEG (247). Open IMV CONTROL BLEED valve until IMV CONTROL PRESS LOW gage indicates zero. Close valve, NO. 1 CLOSED and NO. 2 CLOSED lights (246) remain on. NO. 1 OPEN and NO, 2 OPEN (242). and gas generator OPEN (243) lights go off. NO. { CLOSED and NO, 2 CLOSED (2A2), and Kas generator CLOSE (2A3) lights come on. CONTROL port is de- pressurized, i. Open HYD Hi- FLOW REG (142) watit HYD HI-FLOW PRESS gage indicates 1,550 +50 psi. ]. Move FOUR-WAY VALVE switch (1A1) to START, 3+28 Engine hydraulic con- trol system is pres- surized, NO. 1 CUOSED and NO. 2 CLOSED (2A2) and gas generator CLOSE (243) lights go off. NO. 1 OPEN and NO. 2 OPEN (242), and gae penerator OPEN (243) lights come on, Change No, 8 - 9 September 1970 nA, Close HYD HI-FLOW SHUTOFF valve (JA2). CAUTION The HYD HI- FLOW SHUTOFF valve must be completely closed before closing the HYD HI-FLOW REG, to proven damage to pressure reducing valve 19-9023747, Oo. Close HYD HIi- FLOW REG (1A2) wutil HYD Hl- FLOW PRUSS gage indicates zero. Kingine hydraulic con- trol system is depres- surized, R- 3896-11 Section WE Paragraph 3,2,3. 11 Procedure result aD. Lubricate (Method A) threads of gas I HY PERGOL CAR- TRIDGE INSTALLED light (2A7) zoes off, 3.2,3.11 Valve Vining Test. p. Release lever on hypergol test tool, a. Verify that engine checkout consule is pre- pared for electrical, pneumatic, and hydraulic operation (paragraph 3,2. 1), a-1A. Perform, 2s applicahle, cuntamina- tion and damage prevention procedures uutlined in paragraph 3,1A when performing this test. aA. Verify that drain hoses ate installed on engine control valve supply tube drain and checkout valve engine return hose drain (para- graph 3.2.3.8), aB. Hemove pressur? cap from, and attach a drain hose to, the following quiek-disconnects: (1) No. 1 fuel high-pressure duet drain (2) No, 2 fuel high-pressure duct drain CAUTION [In the following procedure, during removal of the gas generator ball valve fuel inlet quick-discomect cap, the quick-disconnect body must not be allowed to turn since a terque tlecrease between quick-disconnect body and adapter or adapter and gas generator ball valve fuel housing can result in seal leakage. (3) Gas generator ball valve fuel inlet «eain (4) Turbopump No. 1 fuel inlet elbow drain (5) Turbopump No. 2 fuel inlet elbow drain aC. After completion of drainage from hoses invtalled in step aA, remove draln noses, ex- cept for No, 1 fuel high-pressure duct drain on engines with gimbal actuators installed, Remove pressure caps from packaging, and install pres- sure caps, except for gas generator ball valve fuei inlet drain, on cach quick-disconnect, Torque 3/8-inch pressure caps to 30-40 ft-lb and 3/4-inch pressure caps to 70-75 ft-th. NOTE The method for appiying lubricant in the following procedure is outlined in R- 3896-3. Change No. 8 - 9 September 1970 fenerator ball valve fuel inlet drain quick- disconnect with lubricant grease RBOTMO-012 (Rocketdyne) or FS1281 grease (Dow Corning Corp), and install pressure cap. Torque pres- sure cap to 210-230 im- lb. ak. Safetywire all quick-discannect pressure caps with Inconcl lockwire MS20995N. b. Verify that hydraulic system is connected to engine (paragraph 3.2.3.8), c. Verify that pressure tesl fixture 1s in- stalled between ignition monitor valve sceuse tube Caunge and thrast chamber fuel inlet flange {paragraph 3.2.3.9). dad. Verify that pneumatic hose is installed be- tween ignition monitor valve CONTROL port and IM\V CONT PORT (247) (paragraph 3.2.3.8). e. Verity that on temperature recorder (249) (inside recorder door) MOTOR, LIGHT, and AC LINE switches are on. NOTE Temperature recorder sequires a 5- minute warmup period. cA. Open HYD HI-FLOW SHUTOFF valve (1A2). rocedu) Result f. Open HYD El- FLOW REG (1A2) until HYD Hi- FLOW PRESS gage indi- cates 1,550 420 psi. Hydraulic control sys- tem is pressurized. g. Circulate hydraulic fluid for a minimum of 15 minutes to remove eitrvapped air from hydraulic control system before proceeding with test. h. Turn on facility instrumentation. Record oxidizer valves, fuel valves, and gas generator ball valve timing during steps i through o. 3-28A/3-28B R-3896-11 lL Move FLOWMETER SEL switeh (2A1) to LOW. Proc edure }. Move IMV CON- TROL switeh (247) to AUTOMATIC. k. Make sure INV CONTROL BLEED valve (2A7) is closed. Open IMY CONT PRESS REG until IMV CONTROL, PRESS LOW page indicates 99:5 psi. 1 Move FOUR- WAY VALVE switch (LAt) to START. m. Move FOUR- WAY VALVE switch (1A1) to STOP. Result MANUAL lycht (27) remaiis On. IMV CONTROL PRESS LOW gage indicatyes 30 45 psn. NO. t CLOSED and NG. 2 CLOSED (242). and vas penerator CLOSE (2A3) lights po off. NO. L OPEN und NO. 2 OPEN (2A2), and pas penerator OPEN (243) lights come on. MANUAL hight (2A7) pos off and AUTOMATIC heht comes un. NO. I CLOSED und NO. 2 CLOSED (2A6}) lights yoooff., NO. 1 OPEN and NO. 2 OPEN (246) lights come on. NO. 1 OPEN and NO. 2 OPEN (2A2), yas ven- erator OPEN (3.43), and NO. 1 OPEN and NO. 2 OPEN (2A6) lights vo off. NO. 1 CLOSED and NO. 2 CLOSED (242), gas renerator CLOSE (2A3), and NO. 1 CLOSED and NO. 2 CLOSED (248) lights come on. AUTOMATIC light roes aff, and MANUAT, light comes on. Procedure n. Close IMY CONT PRESS REG (247). Open IMV CONTROL BLEED valve until IMV CONT PRESS gaure mdicates Zero. Close valve. O. Repeat steps k through n 2 addi- tional times. p. Make sure IMV CONTROL BLEED valye (2A7) woclosed. Open IMV CONT PRESS REG until TMV CONTROL PRESS LOW vare indicates 0 + pai. gq. Muyve FOUR- WAY VALVE switeh (TAi} to START and hold. Obtain an ammeter reading and record current drain of start sole- noid: then release switch, r. Monilfor hy- draulic fluid flow- rate on HYD RE- TURN FLOW (2A1). Record flowrate, Change No, Section IH Result Jenition monitor valve CONTROL part is depressui ized, As specilied in steps k through mn, EMV CONTROL, PRESS LOW pape undieates 50 +5 psi. Current drain must not excced 0.60 ane peres. NO. 1 CLOSED and NO. 2 CLOSED (2A2), and fas generator CLOSE (2A3) lights go off, NO. 1 OPEN and NO, 2 OPEN (2A2), and gas gener- autor OPIN (2A3), lights. come on. MANUAL lipht (247) goes off, and AUTO- MATIC light comes on. NO. 1 CLOSED and NO. 2 CLOSED (2A8) lights wo off. NO. 1 OPEN and NO. 2 OPEN (2A6) Jights come on. Flowtrate with vaives open must be 11.6 tl.1 gpm. 1 - 23 April 1969 $-29 Section LIT Paragraph 3.2.9, 12 Procedure s. Pross and hold down REDUNDANT SHUTDOWN VALVE switeh (1A1). Obtain an ammeter reading and record current drain of solenuold; then release switen. t. Move POUR- WAY VALVE switch (141) to STOP and hold. Oblatn an aimmeter reading, and record current drain of solenoid; {hen release switch. u, Monitor hy- draulic fluid flowrate on HYD RETURN FLOW (241). Re- cord flowrate. v. Monitor facility instrumentation re- cord of the 4 timing tests. w. Move IMV CONTROL switch (2A7) to MANUAL, R-3896-11 Result Cuscrent drain wust not exceed 2 OQ ampercs, NO. 1 OPEN aid NO. 2 OPEN (243), andNQ, 1 OPEN and NO, 2 OPEN (2A6) lights po off. NO. 1 CLOSED and NO. 2 CLOSED (242), gas generator CLOSE (29A3), and NO. 1 CLOSED and NO, 2 CLOSED (2A8) lights come on, AUTOMATIC light (2A7) goes off, and MANUAL light comes on. Cuvrent drain must not exceed 0, 60 amperes, Flowrate with valves closed must be 11,6 t1.1 gpm. Valve timing must mect requirements of sec- tion I. MANUAL light remains on. x. Turnofffacilily instrumentation, xA. Close HYD hI- FLOW SHUTOFF valve (1A2). CAUTION The HYD HI- FLOW SHUTOFF valve must be completely closed before closing the HYD Hi- FLOW REG, to prevent damage fo pressure reducing valve 19-9023747. y. Close HYT HI- VLO'TV REG (142) unti] HYD HI- FLOW PRESS gage indicates 2e°0, a. On temperature record raed {inside re- 2 corder door), move MOTOR, LIGHT, and AC LINE switches to OFF. 3-30 Hydraulic control sys- tem is depressurized. Recorder stops Change No. 6 - 10 February 1970 aa. Move FLOWMETER SEL switch (2A) to BYPASS, ab. Vorify thal ignition monitor valve sense tube clamp is disconnected: then remove fasten- ers that secure ipnition monitor valve sense lube to thrust chamber fuel inlet manifold, and remove blank plate from between flanges. ac, Verify alinement of ignition monitor valve sense lube as outlined in R-3898-3, ad, Remove seal plate from packaging, and install seal plate between ignition monitor valve sense tube and thrust chamber fuel inlet mani- fold, Secure tube to manifold with 4 holts, 8 washers, and 4 nuts, ac. Install clamp securing ignition monitor valve sense tube to bracket on thrust chamber fuel inlet manifold, Vorque clamp fasteners to 24-30 ineth, af. Disconnect pneumatic hose from between ignition monitor valve CONTROL port quich~ disconect and (MV CONT PORT (247), ag. Remove engine checkout valve adapter 9022007-11 from ignitlon monitor valve CON- TROL port quick-disconnect. Remove pressure cap from packaging, and install pressuce cap on quick-disconnect, Torque pressure cap to 30-40 ft-lb. Safetywire pressure cap with Inconel lockwire MS20995N. ah. caps on each of the following quick-disconnects, Torque quick-disconnect pressure caps to 30-40 ft-lb. Safetywire pressure caps with Inconel lockwire MS20995N. (1) Engine contro) valve supply tube dain (2) Checkout valve engine return hose drain (8) No, 1 fuel high-pressure duct drain on engines with gimbal actuators installed 3,2.3.12 Fuel Feed System Leak Test. When a flowtester ts specified in this procedure, Pneumatic Flow Tester G3104, or equivalent, must he used, a. Verify that engine ~heckout console is pre- pared for electrical, pneumatic, and hydraulic operation (paragraph 3,2.1). b. Verify that hydraulic system is connected to engine (puragraph 3.2.3.8). bA. Perform, as applicable, contamination and damage procedures outlined in pavagraph 3.1A when performing this test. c. On engines not incorporating MD161 change, rcmove closure from No. 1 fuel pump Torque nuts to 47-57in-Ib, Remove drain hoses and install pressure § It-3896-11 inlet elbow, and install cutboard fuel inlet test plate $0201¢2 not incorporating capilve bolts. Torque pli te fasteners fo 120-155 in-tb, a. On e¢..gines incorporating MD161 change, remove closure dust cover and install outboard fuel inlet test plate 9020162 incorporating caplive Dolts. Torque plate fasteners to 120-155 in-th, e. Connect a fuel hose between plate INLET port and FUEL PUMP INLET port (1A3). f, On engines not incorporating MD161 chauge, remove closure from No. 2 fuel pump inlet elbow, and install inboard fuel inlet test plate 9026161 not incorporating captive bolts, Torque plate fasteners to 120-155 in-lb. 4. On engines incorporating MDUG! change, remove closure dust caver and install inboard fuel inlet test plate 9020161 incorporating caplive bolts, Torque phite fasteners to 120-155 in-lb, gA, Vent exhaust system by removing plug from cither gas generator IGNITER boss, h. Verify thal thrust chamber exit and thrust chamber throat closures are removed and that fuel overboard dvain line at exil end uf thrust chamber is vented to ambient. NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, i. Remove cross-to-~lateral drain tube from between cross and [ue] overboard drain line Y~fitting, and install pressure cap AN929-16C on fuel overboard drain line Y-fitting. Lubri- cate (Method A)threads on line with lubricant grease RBO140-012 (Rocketdyne). Torque pressure cap to 1,200-1,400 in-th, j. Remove fuel drain manifo'd cover plate and seal plate from fucl drain manifold, and install fuel seal drain manifold adapter 9020907, Torque fasteners to 43-47 in-lb. k. Remove plugs from INLET and PRIMARY ports on adapter. kA. Remove pin and closure from hypergol manifold cartridge container inlet port, WARNING The following procedure uses drycleaning solvent, which is flam- mable and must not be used near heat, Sparks, or open flame, Inhalation of its vapors or prolonged contact with the liquid can cause serious Injury, Section Hl NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, kB. Clean threads of hypergol numtfold war- tiidge container inlet port with drycleaning solvent (Federal Specification P-D-68u), Lubricate (Method A) threads with lubricant grease RBO140-012 (Rocketdyne), CAUTION When installing hyperyol simulator into the hypergol manifold cartridge contiiner inlet port, extreme care must be used to prevent damage to the hypergol cartridge follower, @ The threads of the hypergol simu- lator cap must be clean and free of nicks, to prevent galling the threads of the cap and inlet port, kC, Make sure that threads of cap on hyper- 201 simulator T-5029716, or equivalent, are clean and free of nicks; then lubricate (Method L) simulator shaft O-ring with F$1281 prease (Dow Corning Corp), and carefully insert Simulator into hypergo)] manifold cartridge container inlet port, Screw simulator clock- wise until it bottoms, ‘kD, Verify that pressure cap is instalied on union in simulator cap. 1, Remove pressure caps from the following quick-disconnects: (1) No. land No, 2 fuel high-pressure duct drains (2) No. l and No. 2 fuel inlet elbow dreins (3) Engine control valve supply tube drain (4) Checkeul valve engine return hose drain CAUTION In the following procedure, during removal of gas generator ball valve fuel inlet quick-disconnect cap, the quick-disconnect body mus} not be allowed te turn since torque decrease between quick-disconnect body and adapter or adapter and gas generator ball valve fuel housing can result in seal leakage, (5) Gas generator ball valve fuel inlet drain 1A, Open HYD HI «LOW SHUTOFF valve (242), Change No, 12 - 23 August 19°74 3-31 Sectlon OI Provedure m. Open HYD HI- FLOW PEG until HYD HI-FLOW PRESS gage indicates 1,550 250 psi, Monitor hydraulle fluid leakage, n, Slowly open MSL AIR PRESS REG (143) until PUEL PUMYP INLET PRESS gage (1A4) indicates 8045 psi, Move MSL AUt F/M SIL yalve to HIGH (1A3), 0, Using flow- tester, measure and record poppet reverse flow leakage at each quick-disconnect listed in step 1. R-3896-11 Result Brgine hydraulle con- trol is pressurized, No leakage is allowable, Fuel feed system is pressurized, and flowrate is indicated on MISSILE AIR FLOW HIGH flowmeter (1A3), Leakage at each quick- disconnect poppet must not exceed 3 scim. p. Remove pressure caps from packaging, and install pressure caps on quick- disconnects listed in step 1, except for gas generator ball valve fuel inlet drain, Torque 3/8-Inch pressure caps ta 30-40 ft-lb and 3/4-inch pressure caps to 70-75 ft-lb, NOTE The method for applying lubricant in the following procedure is outlined in R-3896~3, pA, Lubricate (Method A) threads of gas generator ball valve fuel inlet drain quick- aisconnect with lubricant grease RBO140-012 (Rocketdyne) or FS1281 grease (Dow Corning Corp), and install pressure cap, Torque pressure cap to 210-230 in-Jh, pB,. Safetywire all quick-disconnect pressure caps with Inconel lockwire MS20995N., q through s. (Deleted) CAUTION Leak-test compound used in the following procedure must not be used on overboard drain line exits to preclude introducing leak-test compound into the Hnes, e Leak-test compound must not be used on flex line bellows since it cannot be removed from the bellows, 3-32 ~hange No, 12 ~ 23 August 1971 Procedure Result t. Using leak-test compound (MIL-L-2556"), or equivalent, monitor leakage at flanges, gimbal yoke bellows, fittings, and Instru- mentation lines on or connected to the following: (1) No. 1 and No, (2) No, 1 and No, (3) No, t and No. (4) Gas venerator fuel feed duct No leakage is allowable, 2 fuel inlet elbows 2 fuel high-pressure ducts 2 fuel valves (5) Gas generator ball valye fuel side (6) Igniter fuel supply tube from No, 1 fuel high-pressure duct to hypergol manifeld igniter fue) inlet port (7) Fuel volute to valve lube feed tube {pump volute to bearing coolunt control valve) (8) Turbopump balance cavity high-pressure tube and turbopump balance cavity return line (9) Engine control valve supply tube from No, 2 fuel high-pressure duct to engine control valve (10) Checkout valve engine return hose tA, Remove cap on torque-gear housing, tB, Attach a torque wrench with an adapter (1-1/16 inch deep socket) and an extension (2 feet long) to torque-pinion-sear shaft, tC, Depress lock- pin on torque-gear Torque-pinion-gear shaft engages turbopump housing, and depress shaft. torque-pinion-gear by applying pressure to adapter, NOTE In the following procedures, one revolution of the turbopump shaft requires 5 revolutions of the turbopump torque gear, u. Using Mlow~ tester, measure leakage past lturbo- pump fuel inlet. Leakage past turbopump fuel inlet seal must not exceed 50 scim. R-3496-11 Procedure Result seal aL INLET port on adapter, Record leakage (turbopump shaft rotating and stationary), Slowly rotate turbepump shaft to determing maximum leakage rate whether rotat- ing or stationary, Leakage past turbo- pump primary fuel seal must not exceed 0 scim, v. Using flow- tester, measure leakage at PRI- MARY port on adapter, Record leakage (turbopumy shaft rotating and stationary). Slowly rotate turbopump shaft to determine maximum leakage rate whether rotat- ing or stationary. w, Wait untll flow of MISSILE AIR FLOW LOW flowmeter or MISSILE AIR FLOW HIGH flowmeter, as applicable, has stabilized for at least 2 minutes. Measure and record total fuel feed system leakape. Procedure aa. Using flow- tester, measure nominal leakage past turbopump pri~ niuiry fuel seal at PRIMARY port on adapter (turbopump shaft stationary), Record results, ab. Remove plug from hypergol mani - fold snstrumentation tap [F3, and using a flowtester, measure leakage past igniter fuel valve poppet, ac. Close MSL AIR PRESS REG (143), and move MSL AIR F/M SEL vaive to BYPASS, ad. Slowly open FUEL PUMP BLEED valve (MANIFOLD BLEED PANEL). Section TE Result Leakag: . ast turbo- pump primary fuel seal must not exceed 50 scim. Maximum allowable leakape at igniter fuel valve poppet is 0.4 scim, Flow through MISSILE AIR FLOW HIGH flow- meter (1A3)} decreases to zero, FUEL PUMP INLET PRESS gage (144) decreases to zero. adA. Close HYD HI-FLOW SHUTOFF valve (1A2). x. Using fiow- tester, measure leak- age at fuel drain disconnected in step i. Record re- suis, y. dJsing Now- tester, measure leakage from fuel overboard drain at thrust chamber exit, Record re- sults. z. Using flow- tester, neasure nominal leakage past turbopump fuel inlet seal at inlet port an adapter (turbopump shaft stationary). Record results. Leakage past gas gen- erator ball valve fuel shaft seal must not ex- veed 0.25 scim. Leakage past bearing coolant control valve check valves must not exceed 2 scim, Leakage past turbo- pump fuel inlet seal must not exceed 50 seim, CAUTION The HYD HI- FLOW SHUTOFF valve must be completely closed before clesing the HYD HI-F LOW KEG, to prevent damage to pressure reducing valve (9-9023747, ae. Close HYD HI~FPLOW REG (142) HYD WI-FLOW PRESS gare (142) decreases {9 zero, af. Add the following leakage rate resuits to ubtain total fuel feed system measured vent leakage rates: (1) Bearing coolant valve check valves leakage (step y) (2) Nominal turbopump fuel inlet seal leakage (step 2) (3) Nominal turbopump primary fuel seal leakage (step aa) Change No. 5 - 9 October 1969 3-33 Section Ll ag. Subtract the total fuel teed system meas- ured vent leakage rate obtained in step af from total fuel feed system measured leakage rate obtained in step w. The result is the calculated leakage rate past checkout valve ENG RE'TURN port ball seal, gas gencrator fuel teed system, and skirt and nose seals of both fuel valves. ah, Tf calewlaicd Jeakage obtained m step ag is ereater than 15 seim, perform checkout valve iyelation leak test as outlined in paragraph 3.2.4.0 and, using this tolal fuel feed system leakage rate, subtract total fuel system meas~ ured vent leakage, step ag, to obtain leakaye vate past gas tenervator fuel feed system and fuel valves slart and nose seal. ar. It gas generator ball valve fuel ball seal and fuel valves skirt and nose seal leakage slilt exceeds Lo scim, perform pas generator fuel feed ee isolation leak test (paragraph 3.4.4.4), aj. H fuel valves skirt and nose seal leakage still execeds 15 scim, perform fuel valves skirt and nose seal isolation leak test (paragraph 3.2.4.5), ak. Remove fuel hose from outboard fuel inlet test plale and FUEL PUMP INLET port (1A3). al, On engines not incorporating MD161 change, remove test plates from No, lana No, 2 fuel pump inlets, remove elosures from packaging, ard install closures on inlets, Tighten closure fasteners fingertight plus 1/4 turn, am. On engines incurporating MD161 change, remove test plates from No, 1 aad Na, 2 fuel pump inlets, remove dust covers from packag- ing, and install dust covers on inlet closures. an. Remove fuel seal drain manifold adapter from fuel drain manifold, remove iuel drain manifold cover plate and seal plate from packag- ing, and reinstall fuel drain manifold cover plate and seal plate removed in step j. Torque bolts to 44-47 in-lb, Safetywire bolts with Inconel] lockwire MS20995N. (Deleted) NOTE The method for applying lubricant in the fulluwing procedure is vullined in R-3896-3. ao and ap. 3-34 Change Na. 12 - 23 August 1971 R- 3996-11 aq. Remove plug and packing froni packaging. Lubricate (Method J) pucking and \Method A) plug with lubricant grease RBO140-012 (Rocketdyne). Install plug and packing in instru- mentition tip TF3. Torque plug to 40-65 in-lb. Safetywire plug with Inconel lockwire MS20995N. WARNING The following procedure uses clean- ing compound, which 1s volatile. Use ina well-ventilated area since the vapors displace the oxygen in the air, resulting in suffocation, ie. Remove alt feak-test compound from joints and fittings with a clean, dry cloth or by Hlushing inaecessible areas with cleaning com- pound (MUl-C-81302), as. Remove torque wrench, extension, and adapter. al. Verify that lockpin on torque-gear hous- ings is fully extended and that torque-pinion- gear shaft is in lockout position, NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, au. Lubricate (Method J) packing with lubri- cant grease RY30140-012 (Rocketdyne); then install packing on torvque-gear housing cap. av. Jiubricate (Method A) threads of torque- gear housing: cap with lubricant grease RBO140-012 (Rocketdyne); then install cap fingertlight on torque-gear housing. Safetywire cap with Inconel lockwire MS20995N. aw. Remove hypergol simulator T-5029716, or equivalent, from hypergol manifold cartridge container inlet port. WARNING The following procedure uses drycleaning solvent, which is flam- mable anc must not be used near heat, sparks, or open flame, Inhalation of its vapors or proloaged contact with the liquid can cause serious Injury, ax. Clean threads of hypergol manifold car~ tridge container inlet port with drycleaning solvent (Federal Specification P-D-680). R-3896~11 NOTE The method for applying hibricant in the following procedure is out- lined in R-3896-3. ay. Remove hypergol manifold cartridge container inlet port closure from packaging. Lubricate (Method L) closure packing with FS1281 grease (Dow Corning Corp). Install closure and secure with attaching pin. 3.2.3,13 LOX Feed System Leak Test. When a flowtester is specified in the procedure, Pneumatic Flow Tester G3104, or equivalent, must be used. a. Verity that engine checkout console is prepared for electrical, pneumatic, and hydraulic operation (paragraph 3.2.1). aA. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3.1A when performing this test. 2B. Verify that exhaust system is vented through gas generator IGNITER boss (para- graph 3.2,3,12). Section III Paragraph 3.2.3.13 Change No. 12 - 73 August 1971 3-34A/3-34B R- 3896-11 hb, Romove protective closures from nitrogen purpe overboard drain line and oxidizer over- board drain line at exit end of thrust chamber, ¢. On engines not incorporating MD161 change, remove protective closure from turbopuimp oxi- dizer inlet, and install oxidizer pump inlet test plate 9020163 not incorporating, captive bolts, ‘Torque plate fasteners to 330-490 in-lb, ad. On engines incorporating MD161 change, remove dust cover and install oxidizer pump inlet test plate 9020163 incorporating captive bolts. Torque plate fasteners to 330-430 in-lb, e, Connect an oxidizer hose between oxidizer pump inlet test plate 9020163 and LOX PUMP INLET port (143), f, Install pluy AN806T8 in nitrogen purge overboard drain line at theust chamber exit. sdal vent tubes land No. 2 oxi- ©, Disconnect actuatar rod from OXID VENT port on No. diver valves. Cap tubes, h, Move LC, AIR F/M SEL valve (143) to BYPASS, Procedure Result, LOX propellant feca system is pressurized, and J,.0X CLEAN AIR FLOW flowmeter (1A3) indicates flow. i. Slowly open L.C. AIR PRESS REG (1A3) until LOX PUMP INLET PR&SS gage (1A4) indicates 8) 35 psi. Move L.C, AIR F/M SEL valve (143) to HIGH, Re- cord pressure, iA, Remove cap on torque-gear housing. iB. Attach a torque wrench with an adapter (1-1/16 inch deep socket) and an extension (2 feet long) to torque-pinion-gear shaft. iC. Depress lock- pin on torque-gear housing, and depress torque-pinion-gear by applying pressure to adapter, Torque-pinion-gear shaft engages turbo- pump shaft. NOTE In the following procedure, one revolution of the turbopump shaft requires 5 revolutions of the turbo- pump torque gear. Section Ill Procedure, Result j. Using flow- tester, measure and record Joakage from oxidizer over- board drain line at thrust chamber exit, Slowly rotate turbo- pump shaft to deter- ming maximam leakage rate whether rotating or stationary, Leakage past turbo- pump primary LOX seal must not exceed 700 seim. k. Using flow- tester, measure and revord leakage at actuator roc OXID VENT port of vach exidizer valyc, Leakage past each bottum rod lipseal must nat exceed 30 scim, Llandm, (Deleted) i CAUTION Leak-test compound used in the following procedure must not be used on overboard drain line exits to preclude introducing leak-test compound into the lines, @ Leak-ftest compound must not be used on flex line bellows since it cannot be removed from the bellows. nh, Using leak- test compound (MIL-L-25567) moni- tor leakaye ai flanges, gimbal yoke bellows, fittings, and instru- mentation lines on or connected to the following: No leakage is allaw- able, except on engines not Incorporating, M1)128 change where fuzz loakape (as defined in section If) is allow~ able between pas gen- ‘ erator ball vaive oxidizer housing and ' actuator cavity housing joint. (1) Oxidizer pump Change No, 8 - 9 September 1970 3-35 Section (Tf (2) No. ducts Land No. 2 oxidizer hogi-pressure (3) No. land No. 2 oxidizer valves (4) Gas generator oxidizer feed line (5) Gas generator ball valve oxidizer side (6) Oxidizer pump inlet to oxidizer pump volute (7) Gas venerator ball valve oxidizer side to actumtor housing (8) No. land No, 2 oxidizer valves cover to housing NOTH In the following proceedure, af leak- ape is less than 30 secim, Pnewnatic Flow Monitor G3131 may be used. Make sure that flowrate of LOX CLEAN AIn FLOW flowmeter (1A3) hag stabilized for at least 2 minutes. Record total LOX propellant feed system leakage. Procedure Result Leakage past turb ump primary LOX seal must not exceed 700 scim. p. Using fow- tester. measure and record leakage at oxidizer overboard draika line (turbo- pump shaft stationary). LOX CLEAN AIR FLOW HIGH flowmeter (1A3) decreases to zero. q. Close L.C. AIR PRESS REG (143), and move &.C. AIR SEL valve to BYPASS. LOX PUMP INLET PRESS gape (1A4) de- creases to zero. r. Slowly open LOX PUMP BLEED valve (MANIFOLD BLEED PANEL). Close valve after pressure decay. s. Add the following measured leakage rates to obtain total 1.OX propcllant feed system meas- ured vent leakage rate: (1) Oxidizer valves bottom rod lp seal leakage rate (stup k) (2) Nominal turbopumyp primary LOX seal leakage rate (step p 3-36 Change No. 6 - 10 February 1970 R-3896-11 t. Sutdract the sum of step s from recoided results of step o and record ag the calculated leakage rate past gas penerator LOX feed sys- tem and skirt and nose seul of both oxidizer valves. u. If calculated leakage (step t) is preater than 10 scim, perform steps v and w, repeat steps 1 through k and o throuph t; then proceed to step x. v. Verify that hydraulic system is connected to engine (paragraph 3.2.3. 8). Procedure Result w. Open HYD IT- FLOW SHUTOFF valve (1A2). Slowly upen HYD Hi- FLOW REG untkl HYD HI- FLOW PRESS pare indicales 1,550 450 psi. Monitor hy~ draulic fluid leakasre, wA. Close HYD HI- FLOW SHUTOFF (1A2). engine hydraulic eon- trol system is pres- surized. No leakage is alluwabte. valve CAUTION The HYD HI- FLOW SHUTOFF valve must be completely closed before closing the HYD HI- FLOW REG, to prevent damage to pressure reducing valve 19-9023747, Clase HYD HI- ¥ LOW REG (1A2). HYD HI- FLOW PRESS gage (1A2) decreases to zero, y. If calculated leakage (step t) is greater than 10 seim wilh hydraulic system pressurized, perform pas generator LOX feed system isoala- tion leak test (paragraph 3. 2. 4.6), v. It leakage after performance of step y is greater than 56 scim, perform oxidizer valves skirt and nose seal isolation leak test as out- lined in paragraph 3. 2,4. 7. aa, On engines not incorporating MD161 change, disconnect oxidizer hose, and remove plate 9020163 from oxidizer inlet by loosening all attaching bolts 3 full turns before removing individual bolts, Remove packaging from oxi- dizer Inlet closure, and install closure on oxi- dizer inlet. Tighten closure fasteners finger- tight plus 1/4 turn, ab, On engines incorporating MIv161 change, disconnect oxidizer hose and remove plate 9020163 from oxidizer inlet closure. Install dust cover on closure. R- 3896-11 NOTE The method for applying lubricant in the following procedure is outlined in R- 3896-3. ac. Remove plugs, lubricate (Method A) fit- tings and (Method G) tubes with lubricant grease RBO140-012 (Rocketdyne), and reinstall actuator rod seal vent tubes and actuator sea) drain tubes. Torque tube coupling nuts to 135-185 in-Ib. ad, Install oxidizer overboard drain line pro- tective closure on drain line at exit ond of thrust chamber. Torque closure fasteners fingertight plus 1/4 turn, ae. Remove pressure tust fixtures E-5039240 and T-5039234 from checkout valve fround return hose and engine control valve ground hydraulic supply hydraulic hose. Insta] plates on hoses. Torque plate fasteners to 35-40 in-1b, af. Remove plug from nitrogen purge cver- board drain line. WARNING The following procedure uses clean- ing compound, which is volatile. Use in a well-ventilated area since the vapors displace the oxygen in the air, resuiting in suffocation. ag. Remove all leak-test compound from joints and fittings with a clean, dry cloth or by flushing inaccessible areas with cleaning com- pow (MIL-C-81302). fo ouah. Remove torque wrench, extension, and 4 adapter, H ai. Verify that lockpin on torque-gear housing fis fully extended and {hai terque-pinion-pgear B shaft is in lockout position, NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, & aj. Lubricate (Methed J) packing with lubri- 7 cant grease RBO140-012 (Rocketdyne); then j install packing on torque-gear housing cap. fe ak, Lubricate (Method A) threads of torque~ A gear housing cap with lubricant grease R 1%30140-012 (Rocketdyne); then install cap § fingertight on terque-gear housing. Safelywire y cap with Incenel lockwire M&:G995N., Section III Paragraph 3,%.3.14 3.2,3,14 Exhaust System Leak Test. a. Verify that engine eheckou. console Is prepared for pneumatic operation (paragraph 3.2.1), aA, Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3.1A when performing this lest. NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, b, Remove plug from instrumentation tap GO2a; then lubricate (Method J) adapter packing and (Method A) adapter union with lubricant grease RBO140-012 (Rockeidyne), and install cngine exhaust system supply adapter 9022043, or equivalent, in gas generator instrumentation tap GO@a. Torque union to 65-80 in-lb. Retain removed hardware for reinstallation. c. Connect an oxidizer-clean hose between adapter 9022043, or equivalent, and GG LOX INJECTOR & LOX DOME PURGE (145). d, Remove either plug from gas generator IGNITER boss; then lubricate (Method J) adapter packing and (Method A) threads of union with lubricant grease RBO140-012 (Rocketdyne), and install engine exhaust system monitor adapter 9025299, or equivalent, in gas generator IG- RITTER boss. Torque union nut to 225-275 in«lb. e. Remove closure from thrust chi var dome and gas generator purge tube, and install LOX dome and gas gencrator LOX purge adapter 9022010 or equivalent, Lubricate (Method J) adapter packing with lubricant grease RB0140-012 (Rocketdyne). Torque adapter fasteners tu 70- 80 in-lb, Verify that all ports on adapter are plugged or capped. f, Connect a tee to acapter 9025299, or equivalent, attach a hai. bleed valve to one end of tue, and close valve. Connect a fuel hose from other end of tee to INSTR TAP DNSTR OF TURB connection (1A5). g. Remove clamp holding turbopump turbine and heat exchanger antifirex shield to provide access to flange seal monitoring port vent hose outlets, Change No, 8 ~ 9 September 19'70 3-37 Section Il meee ee ee he Check that pedestal exhaust sys- tem manitold seal at thrust chamber exit is inflated to speci- fied pressure, i, Open GG LOX PURGE shutoff valve (145). Slowly open nC AIR PRESS REG until PRESS DNSTR OF TURD gage indi- cates 10 +1 pst, j. Remove closure from oxidizer over- board drain line and, using Pucumatic Flow Tester G3104, measura and record reverse- flow leakage past gas generator LOX purge check valve pate, k, Remove plugs, and using Pneumatic Flow Tester G3104, measure and record leakage at the following static seal monitoring ports: (1) Turbine to heat exchanger (on heat exchanger flange) {2) Heat ex- changer to exhaust manifold (on ex- haust manifold) R-38?6-11 Result, Seal must remain in- flated during remain- der of test. Fnglne exhaust syaten is pressurized, and LOX CLEAN AIR PRESS vape (1A5) indicates 10 +1 psi. Maxinium allowable leakage is 25 seim, Maximum allowable leakages are as follows: 10 seim 10 scim 1. Using Pneumalie Flow Tester G3104, or cquivalent, at vent hose outleis, measure and record leakage from the following static seal monitoring ports: (1) Gas gener- ator combustor to turbine manifold in- let (on gas generator tlangre) (2) Gas gener- ator injector to combustor 3-38 Change No. 10 scim 10 scim 12 - 23 August 1971 CAUTION Leak-test compound used in the following procedure must nat be used on flex line hellows since it cannot be removed from the bellows. m. Using leak-test compound (MIL-L- 25567), leak-test the following flanges with leakage monitoring port plugs removed, Procedure (1) ‘Furbine manifold outlet to heat exchanger (2) Heat ex- changer to turbine exhaust manifold (3) Gas gener- ator combustor lo turbine manifold inlet (4) Gas gener- ator injector to combustor Result Fuzz leakage (as de- fined in section ID) is allowable, Fuzz leakage (as de- fined in section If is allowable. No leakage is allowable. No leakage is allowable. NOTE The method for applying lubricant in the following procedure is oullined in R-3896-3. n. Remove from packaging, lubricate (Method A), and install monitoring port plugs removed in step k. (See figure 3-8.} 0, Apply leak- test compound (MIL-L-~25567) to atl flanges, fittings, and instrumentation lines on or connected to the following and record results: No leakage is allowable, except on engines not incorporating MD176 change at flight turbine manifold temperature trausducer where fuzz leakage (as defined in section IJ} is allowable, (1) Gas generator ball valve (downstream of oxidizer ball and fuel bal) (2) Gas generator ball valve to gas gener- alor injector (3) Gas generator combustor It} 3896-11 (4) Turbine exhaust manifold and heat ex- changer (5) Thrust chamber exhaust manifold weld joints CAUTION The exhaust system must be depres- surized as outlined in steps p through y ta prevent contamination of the engine and checkout console systems. Procedure Result p. Close GG LOX PURGE shutoff valve (1A5), Supply pressure to exhaust system stops. q{. Open hand bleed valve on igniter boss adapter antil PRESS DNSTR OF TURB gage indicates zero, Exhaust system is de- pressurized, r. Close LC AIR PRESS REG (145) until LOX CLEAN AIR PRESS gage indicates zero. Console purge system is depressurized. 5. Remove fuel hose from adapter 9025299 and INSTR TAP DNSTR OF TURB, Remove hand bleed valve from adapter, t. Remove oxidizer-clean hose from adapter 9022043 and GG LOX INJRCTOR & LOX NOME PURGE. Remove adapters. NOTK The method for applying lubricant in the following procedure is outlined in R-3896-3, u. Remove plug and K-seal from packagiag, Lubricate (Method A) plug threads with lubri- cant grease RB0140-012 (Rocketdyne), and In- stall plug and K-seal 12100CR4 in ingtrumenta- tion tap GO2a. Torque plug to 80-90 in-lb. Safetywire plug with Inconel] lockwire MS20995N v. (Deleted) w. Deflate exhaust system manifola scal at thrust chamber exit, Seal is depressurized. Section If Parapraph 3.2,3,15 WARNING The folluwing procedure uses clean- ing compound, which is volatile. Use in a well-veatilated area since the vapors displace the oxygen in the air, resulting in suffocation, x. Remove all leak-test ecmpound from joints and fittings with a clean, dry cloth or by flushing inaccessible arcas with cleaning compound (MIT.-C -81302}. y- Install turbopump turbine and heat ex- changer antifirex shicld., Position clamp coupling joiuts within 3 degrees of a Line extend- ing from the centes of the fue) inlet elhows through the turbopump aft support, Torque clamp coupling joint nuts to 85-95 in-lb, 3.2.3.15 LOX Pome and Gas Generator LOX Injector Purge Leak and Fur unction “Test, a. Verify that engine checkuut console is pre- pared for pneumatic operation (paragraph 3.4%. 1) aA. Perform, as ap, Hcable, contamination aud damage prevention procedures outlined in paragraph 3,1A when performing this lest. NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, hb. Remove closure from LOX dome and gas generator LOX fajector purge interface, and install LOX dome and gas generater LOX purge adapter 9022010. Lubsicate (Method J )adapter packing with lubricant grease RBO140-012 (Rocketdyne), ‘Toruue adapter fasteners to 70-90 in-lb. Verify that all pocts on adapter are plugged or capped. c. Connect an oxidizer-clean hose between adapter 9022010 and C'G 1.OX INJECTOR & LOX DOME PURGE (1A5). d. Verify that exhaus! system is vented tnrough gas generator IGNITER boss (paragraph 3.2.3, 12), e, Verify that thrust chamber exit, thrust chamber vhroat, and oxidizer overbuarc. drain line closures are removed and that thrust cham- ber exit is clear during test. Change No. 8 - 9 September 1970 3-39 Section Nl Paragraph 3.2.3. 25 {. Open GG LOK PURGE shutoff valve (1A5). Procedure Result, Airflow through system is verified at gas pen- erator igniter port AMR PRESS page thrust chamber injector indicates 100 45 and overboard drain psi. line or Ly feehime indi- vidual purge system lines. #. Open LC AR PRESS REG (1A5) until LOX CLEAN CAUTION Teak-test compound used in che follow- ing procedure must not be used on overboard drain ling exits to preclude intveducang leak-test compound intro - duced into the tines. 6 Loak-lest compound must not be used on flex line bellows since it cannot be removed from the bellows. h. Apply leak-test compound (MIL-L-2556%) to all joints and fittings of LOX dome and pas generator LOX in- jector purge systen.. LOX CLEAN AIR ae ae (1A5) de- i. Close GG LOX PURGE shutoff valve {(1A5) and LC AIR creases to zero. PRESS REG jandk, (Deleted) WARNING The following procedure uses cleaning compound, which is volatile. Use in a well-ventilated grea since the vapors displace the oxysren in the air, result- ing in suffocation. 3-40 Change No, 8 - 9 September 1970 No leakupre is allowable. R- 3896-11 1, Remove all leak-test Compound from joints and fitlings with a clean dry cloth or by flushing inaccessible #reas with cleaning compaune (MIL-C-81302). 3,2.3.16 Turbopump Bearing Coolant System Leak and Function ‘Lest. a. Verify that engine checkout console is pre- pared for electrical and pneumatic operation {paragraph 3.2.1). aA. Perform, as applicable, convamination and damage prevention proce‘lures autlined in paragraph 3. LA when performing this test. bh. Remove closures from nitrozen purge overbourd rain line and oxidizes overboard drain line at thrust chamber cxit. NOTE The method for applying lubri sant in the following: procedure is outiucd in R-3896-3. ¢. Remove closure from pump seal purye line, and install LOX seal and gas generator actuator purge adapter 9022012, or equivalent, online. Lubricate (Method J) adapter gasket with lubricant grease RBO140-012 (Rocketdyne). Torque adapter fasteners to 70-80 in-lb. d. Install pressure test fixture T-5039241, or equivatent, on fuel overboard drain line at thrust chamber oxit, Lubricate (Method J) fix- ture O-ring with lubricant grease RBO140-012 (tacketdyne), Torque fixtiwe fasteners to 10-15 in-Jb. ce. Connect a fuel hose between pressure test fixture and PRESERVATIVE INLET port (1A2). f. Verily that cross-to-lateral drain tube 1s removed from between cross and fuel overboard drain line (paragraph 3.2.3. 12). R-3896-11 g. Verify that pressure cap AN929-16J is installed on fuel overboard drain line (paragraph 3.2,3, 12), h. Connect an oxidizer-clean hose between adapler on pump seal purge line and LOX PUMP SEAL & GG ACTUATOR PURGE port (145). i. Open LOA PUMP SEAL PURGE shutoff valve (1A5), j. Open LC AIR PRESS REG (1A5) until LOX CLEAN AIR PRESS gage indicales 75 +5 psi. kK. Open PRESERVATIVE INLET 8/0 valve (tA2), CAUTION When pressurizing fuel overboard drain line, pressure in drain system must not exceed lo psig or damaye to drain lire can result, Procedure Result Fuel overboard drain line and fuel drain manifold and lines are pressusized up to bearing coolant valve outlet port. l. Open GNo PRESS REG (iA2) until PRESERVA- TIVE INLET PRESS gape indi- cates 10 41 psi. CAUTION Leak-test compound used in the fol- lowing procedure niust not be used on overboard drain tine exits to preclude introducing leak-test coin- pound into the lines. e@ Leak-test compound must not be used on fiex line bellows since it eannot be removed from the bellows. No leakaye is ajlow- able, m, Apply leak- test compound (MIL~L- 255607) to all joints and fittings on bearing coolant outlet (lube yalve to turbine hearing lube fuel hose) and drain lines n. Close GNa PRESS REG (1A), PRESERVATIVE IN- LET PRESS page (142) decreases to zero, LOK CLEAN ATR PItESS gege (1A5) decreases to zero, Oo. Close LT AIR PICRSS REG (1A5}, Section IU Paragraph 3.2,3.17 p. Close LOX PUMP SEAL PURGE shutoff valve (1A5), q. Disconnect fucl hose frotn PRESERVATIVE INLET port, and pressure test fixlure at fuel overboard drain line. r. Remove pressure test fixture T- 5039241 from fuel overboard drain line. NOTE The method for applying Jubrieant in the following procedure is outlined Hu RSBOE 2, Ss, Remove pressure cap from overboard drain line, and reinstall cross-to-lateral drain tube, Lubricate (Method A} lo -e threads and lubricate (Method G) tube with lubricant grease RBOL40-012 (Rocketdyne), Torque tube counvling nuts to 1,200-1,400 in-Ib. SA. Remove packaging; then clean aud inspec threads of plug $T3950122RKI.001 for adequate silver plating. Replace plug if silver plating is not adequate. Install washer 651912-3 on plug. Do not lubricate plug. Insta plug in gas genera- tor IGNITER boss and torque to 600-650 in-Ib. Safetywire 2 igniter plugs together with Inconel luckwire WS20895N, As an alternate, plug 11S9015-08 with washer 651912-3 or gasket AN901-8C may be used, If washer 651912~-3 is used, instal) plug MS?015-08 in IGNITER boss and torque to 150-200 in-lb. If gasket AN901-8C is used, screw nluy MS9015-08 fingertight into IGNIPTER boss. Check that gasket seats in re- cerred groove on IGNITE bogs: then torque plug to 150-206 in-lb. Safetywire plug with Inconel lockwire MSZ0995N. WARNING The following procedure uses cleaning compound, whichis volatile. Use in # well-ventilated area since the vapurs displace the oxygen in the air, resutt- ing in suffocation. {, Remove all leak-test compound from joints and fitlings with a clean, dry cloth or by Slush- ing inaccessible areas with cleaning compound (MLL.-C-81302), 3.2,3.17 Thrust Charaber Pneumatic Leak fest, When flowtesters are specificd in this procedure, Pneumatic Flow Tester G3iG4, or equivalont, rust be used, a, Install Thrust Chamber Throat Plug G3136 (puragraph 3.6.15), b. Verify that engine checkout console ig pre- pared for pneumatic operation (naragraph 3.2.1), Change No, 9 « 2 Deeember 1970 3-41 Section NI vA. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3,1A when performing this test. c. Remove plug and instal! an oxidizer-clean adapter, incorporating a check valve and a union ANB15-8C, or equivalent, in thrusi chamber dome PURGE 1B port. Connect an oxidizer- clean hose between adapter check valve and GG LOX INJECTOR & LOX DOME PURGE (148). d. Connect a fuel base betweon thrust cham- ber throat plug quick-disconnect and FUEL B.&. LINE (243). ce. Remove closure from prefill check valve. f. Install inlet port half of pressure test fixture T-5037801 on prefill check valve. g. Verify installation of pressure test fixture ¢-5039232 on GOX duct (heat exchanger end) \paragraph 3.2.3.5). Connect an oxidizer- clean hose between adapier and LOX B.S. LINE (2Al). h. Verify installation of hypergoal systom test ‘ool 9021274 (paragiaph 3.2.3. 10). i, Remcve pressure caps from the following quick: disconnects: CAUTION 1a the following procedure, during re- moval of No, land No. 2 fuel injet manifold quick-disconnect pressure saps, the quick-disconnect hody must not be allowed to turn since damage to quick-disconnect body can result. (ft) No. Land No. 2 fuel inlet mcnifold drécns (2) No. land No. 2 fuel valve purge (3) Hypergol manifold drain (4) Hypergo]l manifold purge (5) Ignition monitor valve control 3~42 Change No. 9 - 2 December 1970 R-3896-11 CAUTION In the following step, the gascous nitrogen supply hose must be sup- ported to prevent the weight on the seal valve stem from damaying the seal, iA. Connect a source of gaseous nitrogen to throat plug scal, Using a suilable material, support the gaseous nitrogen supply hose to re- lieve all weight of hose from geal valve stem, Procedure Result Thrust chamber throat j. Pressurize : plug seal is pressurized. § throat plug seal to 50 (+5, +10) psig. Maintain pressure during remainder of test. k. Move F/M SEL handle (2A3) and /LOW- METER SEL handle (2A1} to HIGH. WARNING The following procedure pressurizes the thrust chamber and cun be ex~ tremely hazardous, All personnel must be kept clear of the thrust chamber exit during this test, Thrust chamber Is pressurized, FUEI, BS PRESS PANEL LOW gage (2A4) and LOX BS PRESS PANEL LOW page (2A8%) indicate 30 (40, -3) pi. l. Open GG 1.0% PURGE shutoff valve {$A5), Open LC AIR PRESS REG unti) LOX CLEAN AIR PRESS gage indicates 30 (40, -3) psi, maendn, (Deleted) R~3896-1) o, Verify that LOX dome and gas generator LOX purge adapter 9022010 is installed and that all ports Section II (9) Thrust chamber dome purge port plugs PURGE 1A, PURGE 24, PURGE 2B, NO. 3 onadapter are plugged or capped (paragraph 3.2.3.15). PURGE, and NO. 4 PURGE Procedure p. Remove closure from oxidizet over- beard drain line and, Result Maximum allowable leakage is 10 sciin. If leakage exceeds 10 seim, perform oxidizer dome purge check valve isolation leak test as oullined in paragraph 3.8.4.8. using flowtester, measure and record reverse-flow leak- ase of No. Land No. 2 oxidizer dome purge check valve gates. CAUTION Jveak-tost corapound used in the follow- ing procedure must not be used on flex line bcllows since it cannot be re- moved from the bellows. q. Apply leak-test compound (MIL- L-25567) to all flanges, jittings, and connections on or connected tu the following and record results: (1) Oxidizer valves and fuel valves (down- stream of poppets) (2) Ignition moniter valve sense tube (3) Hypergol manifold oullet hose between hypergol manifold and thrust chamber (4) Joints between thrust chamber dome and injector and between injector and thrust chamber bady (5) Thrust chamber jastrumentation (6) No, 1 and No. 2 oxidizer dome purge check valves (7) Thrust chamber dome and gas gene: - ator oxidizer purge tubes {8} Exposed thrust chamber tube surfaces No leakage is allowable. Procedure xr. Using flow- tester, measure and record poppet reverse-flow leakage at each quick- disconnect listed in step i. s. Using flow- tester, measure and record reverse-flow leakage past the inert prefill check valve gate. Result Leakage at each quick-disconnect poppet must not ex- ceed 3 avim. Meximum allowable leakage is 50 scim. CAUTION The thrust chamber must be depres- surized as outlined in steps t through x, to prevent contamination of the engine and checkout console oxidizer systems. t. Close GG LOX FURGE shutoff valve (1A5). v. Open FUEL BG. 5. BLEED) valve on panel below (2A4) unlil FUEL BS PRES PANEL LOW wage (2A4) indicates sera. v. Open LOX BS BLEED valve on panel below (2A8) until LOX BS PRESS PANEL LOW gage _ (248) indicates zero. w,. Close LC AIR PRESS REG (1A5) until LOX CLEAN AIR PRESS gage indicates zero. Supply pressure to thrust chainber stops. Thrust chamber is dupressurized. Heat exchanger oxi- dizer system is de- pressurized. Checkout console purge system is de- pressurized. a. Close FUEL B.8. BLEED valve on panel below (244), and LOX B.S. BLEED valve on panel below (2A8). Change Nu, 8 - 9 September 1970 3-43 Section IIT Paragraphs 3,2,4, to 3.2.4.1 y. Remove oxidizer-clean hose and pressure test fixture T-5039232 from LOX B.S. LINE (2A1) and GOX duct (heat exchanger end). In- stall protective cover on GOX duct. Tighten fasteners fingertight plus 1/4 turn. 2. Remove fuel hose from thrust chamber throat plug quick-disconnect and FUEL B.S. LINE (2A3). NOTE The method for applying lybricant in the following procedure is outUned in R-~3896-3, aa. Remove oxidizer~-clean hose and adapter from GG LOX INJECTOR & LOX DOME PURGE (1A5) and PURGE 1B port. Remove plug and seal from packaging, lubricate (Method A) plus and (Method R) seal with lubricant grease RBO140-012 (Rocketdyne), and install plug and seal. Torque plug to 20-30 ft-lb, and record plug installation torque value. Safetywire plug with Inconel lockwire MS20995N., ab. Reduce thrust chamber throat plug seal pressure to zero, ac. Remove LOX dome and gas generator LOX purge adapter 9022010, and install closure on LOX dome and gas generator LOX injector parge interface. Tighten fasteners fingertight plus 1/4 turn, CAUTION In the following procedure, instala- tion WE No, t and No. 2 fuel inlet manifold quick-disconnect pressure caps, the quick-disconnert body must not he allowed to turn since damage to the quick-disconnect body can result. ad. Remove pressure caps from packaging, and instal] pressure caps on quick-disconnects listed in step i. Torque pressure caps to 30-40 ft-lb. Safetywire pressure caps wilh Inconel Jockwire M520995N, ae. Remove Thrust Chamber Throat Plug 9 63136 (paragraph 3.6, 16). af. Install thrust chamber throat security | closure as outlined {n paragraph 3.6.13. ag. Remove pin that secures hypergol test tuol cap, and carefully unscrew cap and remove tool from manf{fold, WARNING The following procedure uses dry- cleaning solvent, which is flammable and must notbe used near heat, sparks, or open flame. Inhalation of its vapors or prolonged centact with the liquid can cause serious injury. 3-44 Change No, 9 - 2 Mecember 1970 R-3898-11 ah. Clean threads of hypergol manifold car- tridge container and inlet port with drycleaning solvent (Federal Specification P-D-680), ai, Remove packaging from hypergol mani- fold cartridge container inlet port closure. Lubricate (Method L) closure packing with FSi281 grease (Dow Corning Corp). Install closure and secure with attaching pin. aj. Remove pressure test fixture T-5037801 and install closure on inert prefill check valve. Tighten fasteners fingertight plus 1/4 turn. WARNING The following procedure uses clean- ing compound, which is volatile. Use in a well-ventilated area since the vapors displace the oxygen in the air, resulting in suffocation. ak. Remove all leak-test compound from joints and fitlings with a clean, dry cloth, or by flughing inaccessible areas with cleaning com- pound (MIL-C-81302}. 3.2.4 ISOLATION TEST PROCEDURES FOR UNINSTALLED ENGINES, 3.2.4.1 LOX Dump Seal Isolation Vest. This test is required only in the event flowrate past the turbopump intermediate seal is zero. This test determines if the purge supply or the sys- tem cverboard drain lines ave obstructed. Zero flowrate of the geal is acceptable. a. With LOX pump seal pure system pres- surized at 85 +10 psig (refer to paragraph 3.2.3.3), rotate turbopump shaft approximately 2 revolutions and repeat leakage measurement at overboard drain lines. if leakaye i3 within limits, continue test. (Refer to paragraph 3.2.3.3.) aA. Perform, 2s applicable, contamination and damage prevention procedures outlined in paragraph 3.1A when performing this test. b. If flawrate is not experienced from both sides of turbopump intermedate seal, backflow the turbopumip intermediate seal from LOX side as follows: (1) Close LC AIR PRESS REG (1A5) until 1OX CLEAN AIR PRESS gage indicates zerc, (2) Disconnect hose from LOX pump seal purge interface. R-3896-11 (3) On engines not incorporating MD161 change, remove protective closure from turbo- pump oxidizer inlet, and install oxidizer pump inlet test plate 9020163 ct incorporating captive bolts. Torque plate faslencrs to 330-43v ia-lb, (4) On engines incorporating MD161 change, remove dust cover and install oxidizer pump in- let test plate 9020163 incorporating captive belts. Torque plate fasteners to 330-430 in-Jb. (5) Connect an oxidizer hose between oxi- dizer pump inlet test plate 9020163 and LOX PUMP INLET port (1A3). (6) Disconnect oxidizer seal vent tube from oxidizer drain tube. Loosen tube clamps, as required to gain access to oxidizer drain tube, CAUTION In the following procedure, the pres- surization supply line must not be attached to oxidizer overboard d.ain tube at thrust chamber exit. (7) Connect an oxidizer hose between LOX BS LINE port (2A1) and oxidizer drain tube. (8) Move L.C, AIR F/M SEL valve (143) to BYPASS, (9) Slowly open LC. AIR PRESS REG (1A3) until LOX PUMP INLET PRESS gage (1A4) indicates 30 (+0, -5) psi (10) Move FILOWMETER SEL valve (2A1) lo BYPASS. (11) Slowly open L.C. AIR HIGH PRESS REG (2A1) until LOW pressure gage (248) indi- cates 20 (+0, -5) psi, and backflow the lurbo- pump intermediate seal from LOX side allowing flow to go overboard through nitrogen purge overboard drain line and LOX pump seal purge interface. (12) Verify flow from LOX pump seal purge interface and nitrogen overboard drain line, (13) Close L.C. AIR HIGH PRESS REG (2A1) until LOW pressure gage (2A8) Indicates Zero, (14) Close LC. AIR PRESS REG (1A3), and open LOX PUMP BLEED valve (MANIFOLD BLEED PANEL) untit LOX PUMPINLET PRESS gage (1A4) decreases to zero, Close valve after pressure decay, Section DI Paragraph 3.2.4.2 (15) Disconnect oxidizer hose between LOX 8S LINE port (2A1) and LCX drain tube, NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3. (16) Lubricate (Method A) threads of oxidizer drain tube and (Method G) oxidizer seal vent tube with lubricant grease RBV140-012 (Rocketdyne), and instal] oxidizer seal vent tube. Torque tube coupling nut to 1,500-1,800 in-lh. Secure clamps, as required, (17) On engines not incorporating MD161 change, disconnect oxidizer hose, and remove plate 9020163 from oxidizer inlet ‘by loosening all attaching bolts 3 full turns before removing individual bolts. Remove packaging from oxi- dizer inlet closure, and install oxidizer inlet closure on oxidizer inlet. Tighten clusure fasteners fingei tight plus 1/4 turn. (18) On engines incorporating WiD161 change, discennect oxidize: hose and remove plate 9020163 incorporating captive bolts, frora oxidizer inlet closure. Install dust cover on closure. (19) Reconnect hose to LOX pump seal purge Interface disconnected in substep 2. (20) Verify leakage from both sides of turboyrump intermediate seal as outlined in para- graph 3,%.3.3. 3.2.4.2 Fuel Grerboard Drain. fine I Isolation Test. This test is required only in event of ex- cessive leakage from fuel overboard drain line. a. Close HYD HI- FLOW SHUTOFF valve (1A2). CAUTION The HYD HI- FLOW SHUTOFF valve must be completely closed before closing the HYD HI- FLOW REG, to prevent dimage to pressure reducing valve 19-9025747. Resut Procedure HYD HI- FLOW PRESS gage ({A2) indicates 7€TO. aA. Close HYD i- FLOW REG (1A2). Change No. 8 - 9 September 1970 3-45 Section IU Procedure Result b. Close IMV CONT PRESS REG (247) until IMV CONTROL PRESS LOW gage indicates zero, Ignition monitor valve CONTROL port is depressurized, c. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3,1A when performing this vest, d. Remove redundant shutdown valve over- ride line from between redundant shutdown valve and engine control valve as follows: {1} Remove attaching hardware that secures line to redundant shutdown valve. and remove seal plate. Refer to R-3896-3 for handling in- formation. Retain attaching hardware for re- installation if acceptable for reuse in accordance with section IL. NOTE The method for applying lubricant in the following procedure is out- lined in R-3896-3. (2) Install pressure test fixture T-5041521 on redundant shutdown valve OUT port. Lubri- § cate (Method J ) fixture O-ring with lubricant grease RBQ140-012 (Rocketdyne). ‘Torque fasteners to 85-95 in-Ib. (3) Disconnect line fron: engine control yalve OVERRIDE port. (4) Protect line from contaminants, and leave line installed on engine, e. Remove control valve override drain tube from between lee and redundant shutdown valve DRAIN port, §, Disconnect tube from ignition monitor valve ATMOS REF port. 3+46 Change No. & - 9 September 1970 R-3896-11 Procedure Open IMV CONT PRESS REG (2A7) until IMV CONTROL PRESS LOW gage indicates 50 +5 psi. Resuit Iguitton monitor valve CONTROL port is pressurized. gA. OpenHYD Hi- FLOW SHUTOFF valve (1A2). h. Open HYD HI- FLOW REG (1A2) until HYD Hi- FLOW PRESS gage indicates 1,550 250 psi. Maintain this pressure for 5 minutes minimum while per- forming step i. Hydraulic control system is pressur-~ ized. i. Monitor and record hydraulic fluid leakage at: (1) Ignition moni- tor valve ATMOS REF port, (2) Engine con- tro] valve OVER- RIDE port. (3) Redundant shutdown valve BRAIN port. 5 ec/m maximum 5 ec/m maximuni 2¢c/m maximum j. Verify that hydraulic fluid has circulated for a minimum of 15 minutes to remove en- trapped air from hydraulic coutrol system be- fore proceeding with test. k. Move FOUR- WAY VALVE switch (1A1) to START position. Engine control valve stait solenoid is energized. NO. J CLOSED and NO. 2 CLOSED (2A2), gas generator CLOSE (2A3), and NO. 1 CLOSED and NQ, 2 CLOSED (¢A6) lights yo off, NO, 7 OPEN and NO. 2 OPEN (2A2), and gas gener- ator OPEN (2A3), and NO. 1 OPEN and NO. 2 OPEN (2A8) lights come on. Procedure lL. Repeat step i. m. Cpen HYD HI- FLOW REG (1A2) until HYD HI- FLOW PRESS gage indicates 1,800 +50 psi. Main- tain ‘his pressure for 5 minutes minimum, hn. Repeat step i. o. Close HYD HI- FLOW REG (1A2) until HYD HI- FLOW PRESS gage indicates 1,550 +90 psi. R- 3896-11 Resul As specified instep i. Hydraulic control systern pressure is increased, As specified instep i. System pressure de- creases and stabilizes. WARNING The following procedure energizes the redundant shutdown valve solenoid, which causes the valve housing to heat up. After electrical power has been applied continuously, the valve solenoid case temperature can cause injury to personnel touching the case. @ if the redurdant shutdown valve is kept enerfized for more than 15 minutes, the solenoid temperature increase will cause the valve to actuate slower. p. Press and hold REDUNDANT SHUT- DOWN VALVE switch (JA1) q. After hydraulic systen) has been pres- surized for a minimum of 2 minutes, monitor and record fluid leak- age at redundant shut- down valve DRAIN port, Redundant shutdown valve is energized. Leakage past drain port seal must not exceed 2 cc/im. Procedure r. Release RE- DUNDANT SHUT- DOWN VALVE switch (1A1). s. HOLD FOUR- WAY VALVE switch {1A1) in STOP and monitor OVEMRINE port for leakage; then release switch. Section ITI Result Redundant shutdown valve solenoid is de- energized, Leakage past OVER- RIDE port must not ex- ceed 5cc/m. NO. 1 OPEN and NO. 2 OPEN (2A2), gas generator OPEN (2A3), and NO. 1 OPEN and NO. 2OPEN (246) lights go off. NO, 1 CLOSED and NO. 2 CLOSED (2A2), gas generator CLOSE (2A3), and NO, 1 CLOSED and NO. 2 CLOSED (2A6) lights come on. sA. Close HYD HI- FLOW SHUTOFES valve (1A2). CAUTION The HYD HI- FLOW SHUTOFF valve must be completely closed before closing the HYD HI- FLOW REG, to prevent damage to pressure reducing valve 19-9023747, t. Close HYD HI- FLOW REG (142). u. Close IMV CONT PRESS REG (2A7) until IMV CON- TROL PRESS LOW gage indicates zero, HYP HI- FLOW PRESS gage decreases to zero. Ignition monitor valve CONTROL port is de- pressurized, NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3. v. Remove plugs, lubricate (Mcthor A) fil- lings and (Method %) tube with lubricant grease HB0140-012 (Rocketdyne), and install control valve override drain tube hetween tee and re- dundant shutdown valve DRAIN port, Torque tube coupling nuts te 135-185 in-ib. Change No. 8 - 9 September 1970 3-47 Section Il Paragraph 3,2.4.3 w,. Remove pressure test fixture T-5041521; then remove packaging, and install redundant shutdown valve override line as follows: (1) Install seal plate between line flange and redundant shutdown valve OUT port, Se- cure line to valve with 4 bolts and washers. Torque bolts to 85-95 in-lb. Safetywire bolts with Inconel lockwire MS20995N, (2) Connect line to engine control valve OVERRIDE port. Torque coupling nul. During last 1/2 turn prior to seating flare, record maximum torque, Torque must be 50-200 in-lb. Continue to torque coupling nut to 270-340 In-ib above recordeu torque. wA, Open HYD HI- FLOW SHUTOFF valve (1A). Result Xx. Open HYD HI- FLOW REG (142) until HYD HI- FLOW PRESS gage indicates 1,950 150 psi. Hydraulic control sys- tem is pressurized, WARNING The following procedure energizes the redundant shutdown valve sole- noid, which causes the valve housing to heat up. After electrical power has been applied continuously, the valve solenoid case temperature can cause injury to personnel touch- ing the case. CAUTION I{ the redundant shutdown valve is kept energized for more than 15 minutes, the solenoid temperature buildup will cause the valve to actuate slower, Kngine control valve OVERRIDE port is pressurized, y. Press and hold REDUNDANT SHUT- DOWN VALVE switch (IAI). z. Monitor redun- dant shutdown valve override Hine comnec- tion fox leakage. aa. Open HYD HI- FLOW REG (A2) until HYD HI- FLOW PRESS gage indicates 1,900 +50 psi. Hydraulic control sys- tem pressure is in- creased, 3-48 Change No + 9 September 1970 No leakage is allowable. R-3896-11 Procedure eb. Repeat step y. ac. Close HYD HI- FLOW REG (1A2) until HYD i1-FLOW PRESS gage indicates 1,550 +50 psi. As specified in step y, System pressure de- creases and stabilizes, CAUTION The following procedure deenergizes the redundant shutdown valve which will cause approximately 25 ce of hydraulic fluid to be expelled from the fuel overboard drain line, Per- sonnel must be kept clear of drain line exit. ad. Release RE- DUNDANT SHUT- Redundant shutdown valve solenoid is de- DOWN VALVE energized, switch (1A1). adA. Close HYD HI- FLOW SHUTOFF valve (1A2). CAUTION The HYD Hi- FLOW SHUTOFF valve rust be completely closed before closing the HYD HI- FLOW REG, to prevent damage to pressure reducing valve 19-9023747. adB. Close ifyD Itl- FLOW REG (142). HYD HI- FLOW PRESS gage (1A2) decreases to zero. HOLE The method for applying lubricant in the following procedure is outlined in R-3896-3. ac, Remove plugs, Jubricate (Method A) fit- ting and (Method G) tube with lubricant grease RBO140-012 (Rocketdyne), and install ignition monitor valve drain tube, Torque coupling nut to 270-345 in-lb. af. Complete hydraulic control system leak and function test as outlined in paragraph 3.2.3.8, 8.4.4.3 Checkout Valve Isolation Leak Test. a. Disconnect hydraulic hose from HYD RE- TURN port (2A1) and connect to AC'T & HYD RETURN TINE port (2A7), R-3896-11 Procedure b, pen HYD Hi- FLOW SHUTOFF valve (1{A2). Slowly open HfYD HI- FLOW REG until HYD HI- FLOW PRESS gage indicates 1,650 459 psi. Monitor hy- draulic fluid leakage. c. Move MSL AIR F/M SEL valve (1A3) to BYPASS, and upen MSL AIR PRESS REG until FUEL PUMP IN- LET PRESS gaye (1A) indicates 80 +5 psi; then move MSL AIR F/M SEL valve (JA3) to TNGH, dg, Wait until flow of MISSILE AIR FLOW HIGH has stabilized for at least 2 minutes, then measure total fuel feed system leakage. Re- cord results. Use results to compute leakage past gas gencrator fuel fecd system and fuel valves skirt and nose seal. e, Close MSL AIR Flow through MISSILE PRESS REG (1A3), AIR FLOW flowmeter and move MSI. AIR (1A?) decreases to F/M SEL valve to ZCPU, BYPASS, f. Slowly open FUEL PUMP BLEF) valve (MANIFOLD BILEED PANEL). Result Engine hydraulic con- trol system is pres- surized. No leakage is allowable. Fuel feed system is pressurized, and flow- rate is indicated on MISSILE AIR FLOW HIGH flowmeter (1A3), FUEL PUMP INLET PRESS gage (1A4) decreases to zero. fA. Close YD W- FLOW SHUTOFE valve (149, CAUTION The HYD Hi-FLOW SHUTOFF valve must be completely closed before closing the HYD H{- FLOW REG, to prevent damage to pressure reducing valve 19-9023747, g. Close IVD W- FLOW REG (1A2). HYD Hi-FLOW PRESS gage (1A2) decreases tu zero. h. Complete fuel feed system leak-test pro- cethive as outlined in paragraph 3.2.3,12. = 2.4.4 Gas Generator Fuel Feed system Se + ee ne oe me oe rane torte REE aD fre ea 2. Porsnn ak as eee contamination and damage prevention procedures outlined in paragraph 3.1A when performing this test. aA, Remove gas gcnerator ball valve shaft fuel seal vent tube connected to banjo fitting on actuator housing, Section III Paragraph 3.2.4.4 CAUTION The orifice plate removed in the fol- lowing procedure is calibrated and must be protected from contamination and damage. b. Remove attaching hardware that secures yas generator fuel duct to No. 2 fuel high- pressure duct, tain orifice plate for reinstallation. reinstallation if aceept- attaching hardware for and remove orifice plate. Re- Retain able for reuse in accordance with requirements of section Tl. NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, c. Install gas genevator fuel feed duct test plate 9025270, or equivalent, between fuel duct and No. 2 fucl high-pressure duct. Lubricate (Method J) plate O-rings with lubricant grease RBO140-012 (Roc ketdyne), to 270-290 in-lb. Torque plate fasteners d. Remove plug from fuel duct port GF1, and install gas generator fucl feed duct adapter 9025274 in port. Lubricate (Method J) adapter packing and (Method A)threads of union with lubricant prease RBO40-012 (Rocketdyne). Torque union nut to 75-100 in-Ib. e. Connect a fuel hose bet yeen adapter and FUEL BS LINE port (243). Procedure {. Open HYD HI- FLOW SHUTOFF vaive (1A2), and slowly open HYD HI- FLOW REG until HYD HI- FLOW PRESS gage indicates 1,550 +50 psi. pe. Open FREON TO FUEL BS shutoff yalve (2A3) until LOW pres- sure gage (2A4) pointer atarts to mave. Close valve. h. Move k/MSEL valve (2A3)to BYPASS, Slowly open FUEL BS REG LOW (2A3) until LOW pressure gage (244) indicates 80 45 psi. Move F/M SEL valve to HIGH, Change No, 8 - 9 September 1970 Result, Engine hydraulic con- trol system is pres- surized, Refrigerant, Type 12 enters gas generator fuel feed system. Gas yenerator fuel feed system is pressur|zed and LOW pressure gape (2/44) indicates 80 45 psl. 3-49 Section UI Paragraph 3.2.4.5 Procedure, Result i, Using Halogen No leakage is ailow- Leak Detector able. 5797934-G1 (General Electric), or equiva- lent, monitor leakage at all joints and fittings of fuel duct and fuel side of gas generator ball valve. Maximum allowable leakage is 0.25 scim. j. Using Pneumatic Flow Tester G3104, or equivalent, meas- ure and record gas generator ball valve fuel shaft seal leak- age at gas generator ball valve fuel vent port. k. Verify that flow on FUBL B.S. LEG HIGH flowmeter (2A3) has stabilized for a minimum of 2 min- utes; thenrecord gas generator fuel ball seal leakage. 1. Move F/MSEL valve (2A3)to BY-~ PASS, Maxirnum allowable leakage is 20 scim, Flaw through FUEL B.S, LKG HIGH flow- meter decreases to Zero. m. Close FUEL BS REG LOW (2A3). LOW pressure gage (2A4) decreases to zero. n, Slowly open bleed (FUEL D.5. BLEED panel). Close valve after pressure decay. nA. Close HYD HI- FLOW SHUTOFF valve (142). CAUTION The HYD HI- FLOW SHUTOFF valve must be ea aah closed before closing the HYD IiJ- FLOW REG, to prevent damage to pressure reducing valve 19-9023747. Close HYD HI- oO. HYD HI- FLOW PRESS FLOW REG (1A2). rate (142) decreases to zero. p. Disconnect gas generator fuel duct, re- move plate 9025270, and reinstall [uel orifice and fuel duct on No. 2 [uel high-pressure duct. Verify that orifice installed is the same one as removed in step b. Torque bolts to 270-290 tn-ib, 3-50 Change No, & - 9 September 1970 R-3896-11 q. Remove fuel hose from adapter 9025271 and FUEL B.S. LINE port. NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3. r. Remove adapter from fuel duct port GF1. Remove plug and packing from packaging; then install plug removed in step din port G1. Lu- bricate (Method J) packing and (Method A) threads of plug with lubricant grease RB0140-012 (Rocketdyne), Torcue plug to 40-65 in-Jb, Safeiywire plug with Inconel lockwire MS20995N, 4@ rA. Remove plugs, lubricate (Method A) fit- lings and (Method GQ) tube with lubricant grease RBO140-012 (Rocketdyne). and install gas gen- erator ball valve shaft fuct seal vent tube re- moved in step a, Torque tube coupling nuts to 135-185 in-Jb. s. Secure system as outlined in paragraph 3.2.3, 12. 3.2.4.5 Fuel Valves Skirt and Nose Seal Isola- tion Leak Test, a. Perform, as applicable, contamination and damage prevention pz ocedures outlined in paragraph 3.41A when performing this test, aA. Remove No. J fuel high-pressure duct as outlined in R-3896-3, b. Install fuel valve inlet test plate 9020155 on No. 1 fuel valve inlet. Torque test plate fasteners to 1,040-1,210 in-Jh. e. Connect a fuel hose between test plate and FUEL B.S. LINE port (2A3). Result Enetne hydraulic control system is pressurized, come Sumy aaron RO. d, Open HYD Hi- FLOW SHUTOFF valve (1A2) and HYD HF-FLOW REG until HYD HI-FLOW PRESS gage indicates 1,559 +50 psi. e. Move F/M SEL valve (2A8) to BYPASS. No, i fucl valve is pressurized, f. Slowly open FUEL BS REG LOW (2A3) until pressure gage (2A4) indicates 80 +5 pst, Procedure g. Move F/M SEL valve (2A3) to HIGH, Measure and record stabilized flow on FUEL B.S. LKG HIGH flowmeter. h, Subtract leakage in step g from leakage in fuel feed system leak test, paragraph 3.2,3.12, step aj. Record results, 4. Close FUEL BS REG LOW (2A3), and move F/M SEL valve to BYPASS, j. Open bleed valve on FUEL B.S, BLEED pane); close valve after pressure decay. R-3896-11 Result Leakage past No. 1 fuel valve skirt and nose seal must not exceed 15 scim. Leakage past No. 2 fuel valve skirt and nose seal must not exceed 15 scim. Flow through FUEL B.S. LKG HIGH flow- meter (243) decreases tu zero, LOW pressure gage (244) decreases to zero, Change No. 6 - 10 February 1970 Section III 3.-50A/3-508 t- 3896-11 jA. Close HYD HI- FLOW SHUTOFF valve (1A2}, CAUTION The HYD HI-FLOW SHUTOFF valve must be completely closed before closing the HYD HI- FLOW REG, to prevent damage te pressure reduc- ing valve 19-9023747, Result Ta arene Procedure HYD fH-FLOW PRESS gage (1A2) decreases to zero, k. Close HYD HI- FLOW REG (142). 1, Remove fuel valve inlet test plate 9020155 from No. 1 fuel valve inlet, and install No, 1 fuel high-pressure duct as outlined iv K-3896-2, m, Secure system as outlined in paragraph 3.2.3, 12, 3.2,4.6 Gas Generator LOX Feed System Isolation Leak Test. When a flowtester is. specificd in this procedure, Pneumatic Flow Tester G3104, cr equivelent, must be used, a. Perform, af appHcable, contamination and damage prevention procedures outlined in paragraph 3.1A when performing this test. aA. Disconnect ball valve shaft oxidizer seal vent tube fram banjo fitting on gas generator ball valve oxidizer vent port. NOTE The orifice plate removed in the following procedure is calibrated and must be protected from con- tanination and damage. h, Remove attaching hardware that secures gas generator oxidizer duct (duct end) to No. 2 oxidizer high-pressure duct, and remove 2 seals and orifice plate, Retain attaching tard. ware for reinstallation, if acceptable for re- use in accordance with requirement of sec« tlon If, Maintain orifice plate in an oxidizer- clean condition, Section Il Paragraph 3.2.4,6 NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, c. Install gas generator oxidizer feed duct test plate 9025266, or equivalent, between gas generator oxidizer duct (duct end) and No. 2 oxidizer high-pressure duct. Lubricate (Method J} plate O-rings with lubricant grease RBO140-012 (Rocketdyne). Torque plata fasteners to 120-130 in-Ih, d, Remove plug from port GOla on gas gener- ator oxidizer duct (valve end). Lubricate (Method J } adapter packing and (Method A) threads of union with lubricant grease RBO140-012 (Rocketdyne) and install gas generator oxidizer feed duct adapter 9025257, or equivalent, in the port. Torgue union nut to 75-100 in-lb. ce. Connect an oxidizer hose between adapter and LOX B.S. LINE port (2A1). Procedure Result {. Open HYD HiI- FLOW SHUTOFF VALVE (142). Slowly open HYD H1- FLOW REG until HYD HI- FLOW PRESS gage indicates 1, 550 150 psi. Engine hydraulic con- trol system is pres- surized. g. Open FREON TO LOX B.S. shutoff valve (2A1) until LOW pressure rave (2A8) pointer starts to move; chen close valve. Refrigerant, Type 12 enters yas generalor LOX feed system. h. Move FLOW- METER SEL valve (2A1) to BY PASS. Slowly open Ll. C. AIR LOW PRESS REG (2A1) until LOW pressure gage (2A8) indicates 80 +5 psl. Move *LOW.- METER SEL valve to LOW. Gas yencrator LOX feed system is pres- surized, and LOW pressure gage (2A8) indicates 80 15 psi. Change No. ¥ ~ 9 September 1970 3-5] Section IIT Paragraph 3.2.4.7 Procedure i. Using Halogen Lexk Detector 9797934-G1 (General Electric), or equiva- lent, monitor leakage et all joints and fittings of LOX feed system and oxidizer side of gas gener- ator ball valve. j. Using flow- tester, measure combined leakage past the gas gener- ator ball valve oxi- dizer shalt seal (ball side) and the oxidizer to actuator housing seal at VENT port. Record leakage. k. Verify LOW PR 293 flowmeter R-3896- Result No leakage is allow- able, Maximum allowable leakage is 10 scim. that flow on LOX B.S. LEAKAGE (2A1) has stabilized for 4a minimum of 2 minutes; then record total gas generator oxidizer feed system leakae i «Subtract leak - age recorded in step j from leakage re- corded in step k. Record calculated leakape, m. Move FLOW- METER SEL valye (241) to BYPASS. n. Close L, C. OG, Slowly open bleed valve (LOX 3,S, BLEED panel}. Close valve after pressure dacay. AIR LOW PRESS Maximum allowable calculated leakage past oxidizer ball seal is 10 seim. Flow through LOX B.S. LEAKAGE LOW! PRESS flowmeter (2A1) decreases to Zero. 5S REG (2A). LOW pressure gages (2A8) decrease to 4erQ, oA. Close HYP Ml-FLOW SHUTOFF valve (1A2}. 3-52 Change No. 8 - 9 September 1970 li CAUTION The HYD HI-FLOW SHUTOFF valve must he completely closed before closing ihe HYD HI-FLOW REG, to prevent aimage {o pressure reducing valve 19-9023747. Procedure Result p. Close HYD HI- HYD HI-iFLOW PRESS FLOW REG (1A2). gage (1A2) decreases to sero, q. Disconnect pas generator oxidizer duct (duet end) from No, 2 oxidizer duct, and remove adapter 9025266. r. Remove packaging and verify that orifice plate is the same as orifice plate removed in step b; then install orifice plate and 2 seals be- tween duct Manges; torque fasteners to 120-130 in-lb, &. Disconnect oxidizer hose from between adapter and LOX B.S, LINE port (2A1). NOTK The method for applying lubricant in the following procedure is outlined in R- 3896-3, t. Remove adapter 9025267 from por! GOla on gas generator oxidizer duct (valve end), and install plug removed in step d. Latbricate ; (Method J) packing and (Methed A) threads of plug with lubricant grease RBO140-012 (docketdyne). Torque plug to 40-80 in-lb. Safetywire plug with Inconel lockwire MS20995N, ue. Remove plug, Jubricate (Method A) banjo fitting threads and (Method G) tube with Ivbri- cant grease REO140-012 (Rocketdyne), and con- nect ball valve shaft oxidizer seal yent tube to banjo fitting on gas generator ball valve oxidizer vent port, Torque tube coupling nut to 135-185 in-1b, v. Secure system as outlined in paragraph 3.2.3.13. 3.2.4.7 Oxidizer Valves Skirt and Nose Seal Isolation Lezk Test. ‘This test is performed only if required by the LOX feed system leak test (par:graph 3.2.3, 13), a. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3,14 when performing this test, tA. Remove No, 1 oxidizer high-pressure duct from engine as outlined in R-3896-3, R-3896-11 b. Install oxidizer valve inlet test plate 9020156 on oxidizer valve inlet. to 1,040-1, 210 in-Jb. plate fasteners Torque test c. Remove oxidizer hose from adapter 9020163 on oxidizer pump inlet. to adapter 9020156, on adapter 9020163, cA, Open HYD Hi- PLOW SHUTOFF valve (142). Procedur *e d, Open HYD HI- FLOW REG (1A2) until HYD HI- FLOW PRESS gage indicates 1,550 +50 psi, Connect hose Pressure cap open port Result Engine hydraulic con- trol system is pres- surized. ec. Move L.C. AIR F/M SEL valve (143) to YPASS. NOTE In the following procedure, if leakage is less than 30 suim on LOX CLISAN AIR FLOW flowmeter (1A3), Pneu- matic Flow Monitor G3131 may be used, f. Slowly open L.C. AIR PRESS REG (143) until LOX PUMP INLET PRESS gage (1A4) indicates 80 +5 pai. Move LC. AIR F/M SEL valve (143) to HIGH. Measure and record stabilized flow on LOX CLEAN AIR YLOW fiowmeter (1A4). g. Subtract leak- age in LOX feed sys- tem Icak test (para- graph 3.4.3. 13, step k) for No. 1 valve from leakage instepf. h. Subtract leak- age in step f plus leak- age in LOXfeed system 1eak test (paragraph 3.2.3,13, step k) tor No, 2 valve from cal- culated skirt and nose seal leakage (parayraph 3.2.3.13, step z). Leakage past No. 1 oxidizer valve skivt and nose seal and actuator rod oxidizer seal is indicated, Loukage past No. | oxidizer valve skirt and nose seal must not exceed 56 scim. Leakage past No. 2 oxidizer valve skirt and nose seal must not exceed 56 scim., Section UI Paragraph 3.2.4.8 Pesult LOX CLEAN AIR FLOW HIGH flowmeter (143) decreases to Zero, LOX PUMP INLET PRESS page (144) de- creases to zero, are ane ncn ar i. Close L.C. AIR PRESS REG (143), and move L..C, AIR F/M SEL valve to BYPASS, j. Open LOX PUMP BLEED valve (on MANT- FOLD BLEED PANEL), Close valve after pres- sure decay. jA. Close HYD HI- FLOW SHUTOFF valve (1A2), CAUTION The HYD HI-FT.OW SHUTOFF valve must be completely closed before closing the HYD HI- FLOW REG, to prevent damage to pressure reducing valve 19-9023747, k. Close HYD HI- FLOW KEG (LA2). HivYbD HWi-FLOW PRESS page (1A2) decreases to zero, lL, Remove oxidizer hose and adapter, m,. Reinstall No, 1 oxidizer high-pressure duct as outlined in R-3896-3, n, Secure system as outlined in paragraph 3.2.3.13. 3.2.4.8 Oxidizer Dome Purge Check Valve Isolation Leak 7 est, a, Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3,1A when porformiing this test. aA. Remove clam,: that sec: res No. 2 oxi- 9 dizer doine purve line to support bracket, Re- tain aitaching hardware for reinstallation, if acceptable for reuse in aecordance with require- ments outlined in section If. b. Remove attaching hardware that secures No, 2 oxidizer dome purge line to No, 2 oxidi-er § dome purge check valve, and carefully remove orifice plate. Retain attaching hardware for re- installation, if acceptable for reuse in accord. ance with requir ements of section H. c. Using Pneunatte Flow Tester G3104, measure reverse-flow leakage of No, 2 oxi- i dizer dome pvi ge check valve ai check valye to line interface, Maximum allowable leakage is 10 scim. d. If leakage in step ¢ is more than 10 scim, replace No. 2 oxidizer dome purge check valve 5 a8 oul) ned in R-3896-3, Change No, 8 - 9 September 1970 3-53 Section [il Paragraphs 3.3 to 3,3,1,2 e. Subtract leakage obtained in step c for No, 2 oxidizer dome purge check valve pate fvom leakage obtained in thrust chamber pnes- matic leak test (paragraph 3,2.3.17, step p) to obtain leakage for No, 1 oxidizer dume purge cheek valve gate. [f leakage of No. 1 oxidizer dome purge check sani gate is more than 10 scim, replace No. 1 oxidizer dome purge check valve gale as outlined in R-3896-3. {through h. (Deleted) i. Remove packaging and install No, 2 oxi- dize" valve dome purge linc as foilows: (1) Verify alinement of line as outlined in It. 3056-3, (2) Install same orifice plate as removed between line and oxidizer dome purge check valve. Secure Hne to valve with 4 bolts and washers. ‘Torque bolts to 33-39 in-Ib., Safety- wire bolts with Inconel lockwire MS20995N, j. Continue tost in paragraph 3.2. 3.17, 4.3 SNSTALUED-ENGINE TE NOTE Section IL niust ve referred tu for requirements of purge syslerns spocified in steps of leak and func- tion test procedures for installed chyimes wiless otherwise specified. 3.3.2 BLMCTIUCAL ‘TESTS FOR INSTALMEL D iD INGINES (See figures 3-3 through 3-5, ) ee oe ee 3-54 Change No. 8 - 9 September 197U ‘EST PROCEDURES, W-3896-11 3.3.1.1 Plight Instrumentation System Punction Test, Test instrumentation used lo perform the flight instrumentation system function test uctivity is provided by the Stage Coutraetor. ‘The test activity when complemented by criteria referenced in section IE requires no additronal mos tructions; therefore, no recommendations are provided for the method vf accomplishing this activits,. ‘Turbopump Heater r Function Test, a. Provide instrumentation to monttor turbopump heater thermostat eyehnp as ind cated by No. 1 bearing temperature transducer at iistrumentation tap Lt, Procedur co een Jesuit b. Provide 190-220 vav to each turbopump heater element (J800, pins Cand D, for No, Ll heater and pins f and I’ for No. 2 heater). Monitor and reeord current dram of ench heater clement. Current drain must be within 7.5 12.5 amperes for each healer element, NOTH Hoainbient temperature is above 95? F, the heater may not eyele. Phesmostats car be Cooled with a spray retrigerant, Type 12 (Federal Specuieation 13-40-1421) applied in short bursts directly on the thermostat, Thermostats mua piek up and drop ou ata No. J bear int, temperature of between 65° and 180° Fas indicate al instrumentation tap Sd, c. Allow bearing healers to eyelo J times. Reeard min- oui end maxi bearing temperature, de Remove ac power supply to each heater element, e. Secure turbopump bearing healer current drain and temperature instrumentaticn. R-3896-11 3,3,1.3 Hypergol Installed Switch Function Test, a. Provide equipment to supply and monitor 28 44 vde to hypergol cartridge switch (119, pins B and C, at engine interface). aA. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3,1A when performing this test. b. Remove pin and closure from hyperpo) miunifold cartridge inlet port. WARNING The following procedure uses dry-~ cleaning solvent, which is flam- mable and must not be used near heat, Sparks, or open flame, Inhalation of its vapors or prolonged vontiet with the liquid can ciuuse serious injury. NOTE The method for applying lubricant in the following procedure is out- lined in R-3A96-3, e. Clean threads of byporpol manifold car- tridge container inlet port with drycleaning selvent (rederal Specification P-1D-680). f Lubricate (Method A)threads wilh lubricant grease RBQI40-032 (Rocketdyne), CAU'TION Wheu installing the hyperpol sys- tem lest tool inte the hypergol manifold cartridge container inlet port, extverne care must be used to preven: damage to the hyperpgul cartridge follower e The threads of the test tool cap nist be clean and free of nicks to prevent galling the threads of the cap and alet port. d. Marke sure that threads of test-tool cap are clean and free of nicks; then lubricate B (Method L) cap packing with FS1281 grease Section NI Paragraphs 3.3.1.3 to 3,3, 1,4 (Dow Corning Corp) and carefully insert hy- pergol system test tool 9021279, or equivalent, into hypergol manifold cartridge container inlet port, and screw cap (clockwise) onto inlet port until cap bottoms. e. Supply 24-30 vde to J19, pin B. Monitor J19, pin C, for zero voltage. f. Depress and hold lever of test tool monitor J19, pin C, for presence of 24-30 vdc. “ug. Release lever, Monitor J19, pin C, for zero voltage, h. Remove de voltage from J19, pin B. i, Remove hypergol system test tool, WARNING The following procedure uses dry- cleaning solvent, which is flam- mable and must not be used near heat, Sparks, or open flame, In- halation of its vapors or prolonged contact with the liquid can cause serious injury, j. Clean threads of hypergol manifold car- tridge container inlet port with drycleaning solvent (Federal Specification P- D-G680}, k. Remove packaging from hypergol manifold cartridge container inset port closure, Taubati- eale (Method J.) closure packing with FS1281 geease (Dow Corning Corp). tistall closure and seeurc with attaching pin, 3.3.1.4 Checkout Valve Timing ‘Test. a. Provide instrumentation to monitor pusi- tion indicators of engine checkout valve (I-18, pin r, engine return position output, and pin s, ground return position output, at engine interface), aA. Perform, as appieable, contanination and damage prevention procedures outlined in paragraph 3,14 when performing this test, b. Connect a drain hose between quick- disconnect on checkout valve return hose and a facility drain. Change No, 8 - 9 September 1970 3-55 Section IIl Paragraphs 3.3,1,.5 to 3.3.1.6 CAUTION ‘To prevent fluid flow into the engine propellant fuel system, hydvantic fluid must not be supplied to the en- gine hydraulic ground supply inter- face during this test. Frocedure eoeult ¢. Supply 24-30 vde to J18, pins p (+)andt (+) at engine fiterface, and cycle cheekuut valve from ground position to engine position, and record its travel time. dad. Supply 24-30 vde to J18, pinsq (+ )andt (-) at enyine interface, and cyele checkoul valve from engine position to ground position, and record ils travel time. ‘Travel time is 0,5 to 3.5 seconds, Travel lime is 0.5 to 3.5 seconds, e. Repeat steps ¢ and d 2 additional times. f. Remove de voltage from J18, pin q. ye. Turn off instrumentation. h. Remove drain hose (installed in step b} tron quick-disconnect. Remove pressure cap from packaging, and install pressure cap on quickedisconnect. ‘Torque pressure cap to 30-40 ft-lb. Satetywire pressure cap with Inconel Jockwire MS20995N, nay ont cirenits or red lines (listed in section If) is atlained when a malfunetton occurs, Refer to section Lf for detall requirements, $.3.1.6 Ungine Sequence Verification ‘Vest. a. Remove protective closures fram over- bourd drain lines and thrust chambLar throat, aA. Perform, as applicable, contamination and damage prevention procedures oullined tn paragraph 3.74 when perforndny this test. b. Verify that stage pre-valves are closed; then vent the fue) feed system between pre- valves andengine fuel valves during this test by installing drainhoses on No. 1 and No, 2 fuel high-pressure duct drain quick-disconnects, bA, Remove pressure cap from, and attach a drain hose to, the following quick- disconnects: (1) Checkout valve engine return hose 3-56 Change No, 8 - 9 September 1970 R-3896-11 CAUTION In the following procedure, during re- moval of the gas generator ball valye fuel inlet quick-disconnect pressure cap, the quick~disconnect body must not be allowed to turn since a torque deerease between quick-disconnect body and adapter or adapter and gas generator hall valve fuel housing can result in seal leakage. &) Gas generator ball valve fueliniet drain c. Remove electrical connector from engine cheekuul valve actuator. d. Simujate that gas generator and nozzle extension Igniters are installed. e. Remove pin and closure from hypergol manifold cartridge container inlet port, WARNING The following procedure uses dry- cleaning solvent, which 1s flammable and must not be used near heat, Sparks, or apen flame, Inhalation of its vapors or prolonged contact with the liquid can cause serious injury, NOTE The method for applying lubricant in the foliowing procedure is outlined in R-~3896-3. {f, Clean threads of hypergol mantfold car- anidge coutainer inlet port with drycleaning solvent (federal Specification P-D-630). Lubri- vate (Method A) threads with lubricant grease REO140-012 (Rocketdyne). CAUTION When installing the hypergol system {esl tool into the hypergol manifold cartyldge container inlet port, ex- treme care must be used to prevent damaye to the hypergol cartridge follower, @ The threads of the test too) cap must be clean and free of nicks to prevent galling the threads of the cap and inlet port. g. Make sure that threads of Lest-tool cap are clean and free of nicks; then lubricate (Mrthod L) f cap pcchineg with FS$1281 grease (Dow Corning Corp); ; and carefull : reese gethe ,or beet has sad eed manifold cartridge containcs inlet port, and screw ca (clockwise) onto inlet port: ti " : y insert hypergol system teat too witil cap bottoms. R-3896-11 h, Simulate that hypergol cartridge is in- stalled by depressing handle of test tool 9021279, or equivalent, i, Remove pressure cap from and connect 2 gaseous nitrogen supply (MIL- P-27401) to igni- hon monitor valve CONTROL port quick- disconnect. j. Turn on turhopump LOX seal purge. Procedure Result k. Fressurize emone hydraulic control system to provide hydrautie fluid at 1,560 150 psig. Engine hydraulic control system is pressurized, 1. Provide instrumentation for monitoring and engine propellant valves, engine control valve, redundent shutdown vatve, cheekout valve, and hyperpol mstalled switch. (See fipnves 3-3 and 3-4, ) m. Simulate or turn an operational low- level LOX done and gas generator LOX myeetor purge, NOTE Simulate is defined as placement of purge coutvot valves in a position that will allow the sequencing: re~ quired with purge control pressure at zero psig, nh Simulate that engine checkout valve travels to engine position, oOo. Momentarily supply 500-750 vae to each sas generator and each nozzlo exteasior igniter siralator; then verlfy igniter firing voltage presence at cach igniler simulator. p. Supply 24-30 vde to engine cantrol valve start solenold {J-18, ping n (4) and m (-)at engine interface). Record oxidizer valve and gas generator ball valve opening times and sequence times from engine control valve start signal. q. Simulate hypergol burst by releasing plunger of hypergo! test teol, or equivalent. Verily that hypergol instailed switch is de- energized. Section II r, Supply gaseous nitrogen (MIL-P~27401) at 50 +10 psig to ignition monitor valve CONTROL port. Record fuel valve opening times. s, Supply gaseous nitrogen (MIL-P-27401) at 1,240 +30 psi¢ to thrust OK pressure switeh checkout connection. Verify No, 1, No. 2, and No. 3 switch pickup. t, Remove de voltage from J-18, pin h, and supply 24-30 vde to engine control valve stop solenoid (J-18, pin g (4) and & (-) and redundant shutdown valve solenoid (J-19, pins D (4) and L, (-) at engine interface), Record fuel valves, fas generator ball valve, and oxidizer valve closing times, u. Record time delay from cngine control valve stop solenoid signa! to valve movement. ¥. Remove de voltage from J-18 and J-19. Ww, Vent gaseous nitrogen supply pressure from thrust OK pressure switch checkout supply system. Verify No. 1, No. 2, and No, 3 pres- sure switeh dropout (J-20, pins E and F; J-142, pins A and B; and J-174, pins A and B), x. Decrease gascous nitrogen supply pres- sure to ignition monitor valve CONTROL port to zero, and remove nitrogen supply Jine, Re- move pressure cap from packaping and, install pressure cap on CONTROL port quick- disconnect. Torque pressure cap to 30-40 ft-lb, Safetywire pressure cap with Inconel lockwire M2000 oN, y. Depressurize engine hydraulic control system, 2. Turn off turbopump [4X seal purge, aa. Turn off operational low-level LOX dome and gas generator LOX injector purge. ab, Remove hypergol system test tool, WARNING The following procedure uses dry- cleaning solvent, which 1s tlam- mabie and must not be used near beat, sparks, or open flame. Tne halation of its vapors or prolonged contact with the liquid can cause serious injury. ac. Clean threads of hypergol manifold car- tridge container inlet port with drycleaning solvent (Federal Specification P-1D-G80), Change No, 6 » 10 February 1970 3~57 Section IT] Paragraph 3,3.1,7 NOTE The method for applying lubricant in the following procedure ig outlined in R-3896-3, ad. Remove packaging from hypergol mani- fold cartridge container inlet port clusure. Lubricate (Method L) closure packing with F'S1281 grease (Dow Corning Corp). Install closure and secure with attaching pin, ae. Reinstall overboard drain covers and thrust chamber throat security closure (para- graph 3.6.13). af. Reinslall engine electrical connector to engine checkout valve actuator, Refer to R-$896-3 for installation method of electrical connectors, Torque connector to 60-68 in-]b. Safetywire connector with Inconel lockwire MS20995N, ag. Remove drain hoses instaNed in steps b and bA. Remove pressure caps froin packaging, and install pressure caps, except for gas gen- erator hall valve fuel inlet drain, on quick- disconnects, Torque pressure caps to 30-40 ft-lb, ah. Liutbricate (Method A) threads of gas generator hall valve fuel {nlet drain quick- disconnect with lubricant grease RB0140-012 (Rocketdyne) or FS1281 grease (Dow Corning Corp), and install pressure cap. Torque pres- sure cap lo 210-230 in-Ib. ai, Safetywire all quick-cisconnect pressure caps with Incone! lockwire MS20905N, 3.3.1.7 Igniter ‘Test. WARNING A shorting ov shielding cap must be installed on igniters at all times except during testing or igniter harness connection, to prevent accldental Mring resulting in injury to personnel and damage to equipment. NOTE A shlelding cap must be used on igniters at KSC during igniter {nstalirtlon and until igniter harness 1s connected, a, Observe all safety precautions; wear protective clothing specified in section II. 3-68 Change No. 9 - 2 December 1970 R-3896-11 b. Cheek that 6 months have not pussed Since igniter was removed from container, Igniter must be tagged with date of opening of hermetically sealed container. c. Visually inspect igniter, and reject igniter if any of the following conditions exist: (t) Igniter closure damaged (2) Receptacle threads damaged (3) Receptacle pins bent or loose (4) Gasket or gasket seating surfaces nicked or scratched (5) Overage (2 years maximum) d. Using High-Voltage Igniter ‘Tester G3153, or equivalent, perforr 4 current and resistance lest as outlined in ste 4 « chrough j. WARNING The igniter must be in a vented, closed metal centainer or behind a protective shield during the current and resistance test to prevent injury to personnel during accidental firing of the igniter, NOTE Prio uv the test, verification must be made that the teste has been calibrated according to the instruc- tion plate on the tester, The igniter and tester connector cnds must be dry when the igniter is tested, Procedure Result e. Set tester to NO FIRE ‘TEST posi- tion lo check squib circuit (pins B to D) at 250 volts, f, Select FIRE TEST position to check squib circuit (pins B to D) at 500 volts, g. Select 1 INSULA- Meter indicates 100 TION TEST position megohms minimum, to check pin Dto shell. Meter indicates less {han one milllampere, Meter indicates 3,5 to 8 milliamperes. R- 3896-11 Section III Paragraph 3,3.1.8 Procedure Result, h, Select 2 posi- Meter indicates 100 tion (ink) to check megohns minimum. pin C to shell, i, Select 3 posi- Meter indicates 100 tion (link to squib) to megohims minimuin. check pin B to A, j. Select LINK Meter incltcates in position to check green area, pin A to C, NOTE To prevent overexposure of squib and diode to checkout current in the FIRE TEST position, the tester incorporates a delay timer circuit. Before rejecting an igniter, repeat steps d through j, 3.3.1.8 Inert Ipniter Test. ee ere ee mace a nem a. Visually inapect inert igniter, and reject inert igniter {f any of the following conditions exist: (1) Igniter closure damaged (2) Receptacle threads damaged (3) Reeeptacle pins bent or loose (4) Gasket or gasket seating surfaces nicked or scratched aA, Remove shorting or shielding cap aud connect inert igniter to High-Voltage Igniter Tester G3153, or equivalent. NOTE A shiclding cap must be used on ignilers at KSC during igniter jnustallation and until igniter harness is connected, Change No. 9 - 2 December 1970 3-58A/3-58B Procedure b. Turn TOST SELECT switch to NO FIRE TEST po- sition, and press POWER and TEST switches. c. Furn TEST SELECT switeh to FIRE TEST position, and press POWER and ‘PEST switches. ad. Turn TEST SELECT switch to LINSULATION THST position, and press POWER and ThST switches, e. Tork TEST SELECT switch to 2 positions, and press POWER and ThST switches, f.. Turn TST SELECT switch to 3 position, and press POWER and THST pwilehes, #. Move TEST SELECT switeh to LINK position, anc press POWRR and TST switehes, R-3896-11 Result POWER Light comes on and FIRE, NO FIRE TEST meter indicates less than am omilhampere, POWER Tight cames on and FYRE/NO FIRM TEST meter indicates less than one mifhampere. POWER light comes on, and INSULA‘TION/ LINK TEST meter indicates 100 mep- oluns or proater {black area), POWER Lipht cones on, want INSULATION/ LINK TEST meter indicates 160 mep- ohms oy greater (black area), POWER light comes on, and INSULATION? LINK TRST meter indicates 100 mep- ohins or greater (black area}, POWER tipsht comes on und INSULATION / LINK THS’T meter indicator moves to preen area, h, Move Ths‘? select switch ta OFF posi- tion, disconnect testey From inert ipniter, and secure test equipment, i. Using mepohrometer, apply 500 vde for §-60 seconds between pan Band case, and pias Aand DD. Resistanee of cach application niaust exceed 200 meponiny. ee re ree nero nce NT OR fe mE BN A rar Te a. To prepare the vibration safety witol (VSC) tor uperation, a preoperation cutoff test and a preaperation tap test of (he vibration Section Ill Paragraph 3.3.1.9 safety cutoff set must be performed, The cutoff lust verifies the specifie settinys at which the vibration safety eutoff operates during an engine static test, During the cutoff test, il the aceclerometer attenuator dial setting and the eee gee d dial seiting variations become greater than 5 percent of the established recorded settings, the test must be termuinated and the VSC unit removed and rephiced with a calibra - ted unit, The defective umt must be assipned for repair. CAUTION In (he following procedure, torque must not exceed 20 in-Ib a¢ the accelerometer may be twisted otf. The accelerometer cable plust be disconnected (if attached) prior to installation of the aceclerometer, to prevent possinle twisting. The acecleroaetor is a sensitive in- Strument that ean ve danniued by rough treatment, suchas draupping, sharp blows, or overtorquing, a. Verify thal accelerometers are acceptable for use; then install aceclerometers in laps CZAL-Y, CZA10-Y, and CZA4-¥. Torque uccelerometers to 16-20 in-lb, aA. Verify that accelerometer electrical thread protectors are installed until ready to conneck ace elermeter cable. hb, Connect and secure acceler meter cable, Do nol scecuce accelerometer cable to cryopenis lines or surfaces, Verify that cable is not twisted or damaped. NOTE An improperly secured accetero- meter cable may cause hammering sipnals to be transferred to the YSC system. @ Steps ¢ through o outline the pro- cedure for performing a pre- operation cutoff test if one or two VSC systems ure used. Tf two are used, the steps must be repeated on each VSC unit, Proceed to step pif three VSC systems ure used, c. Actuate isolation amplifier and cutoff unit power switches to ON, and allow 15 minutes for temperature stabilization. d. Actuate cutoff unit DISABLE-ARM switch to ARM position. ARM light comes on. Change No, 5 - 9 October 1969 3~59 Section JH e, Disconnect accelerometer cable from isulator amplifier input connector. f. Connect signal generator and an ac voli- meter (with a minimum range of 0, 10 t» 3.00 volts rms, a minimum accuracy of 2 percent, anda minimum input impedance of one megohm) to isolation amplifier input connector, Set signal generator outpul frequency at 2,000 .20 cps and oulput voltage to less than 0,25 volt rns. g. Slowly increase signal generator outpué voltage until CUTOFF light comes on and ARM light goes off on VIBRATION SAFETY CUTOFF panel, h. Vottage reading must be within 5 percent of Vy value recorded on VSC-unil cheek form, It voltage reading is not as required, recalibrate VSC system as outlined in J-2 Rocket Engine Ground Support Equipment Maintenance and Repair Manual R-3825-5, The following cqyua- tion may be used for computing input voltage tu the isolation amplifier using accelerometer charge sensitivity data: _ 11,0009... vie cxT Ge vier Voltage sensitivity at amplifier input in millivolts/g Chavge sensitivity in pieo- caulomb/g (average of 5 charge sensilivities obtained from the General Kleetric Calibration- Maintenance Report) wt * Accelerometer capacitance in picofarads (obtained from the General Electriel Calibration- Maintenance Report) Ct = Total external capacitance in picofarads (measured line capacitanee plus amplifier Input capacitance) Gc = Desired g-level for cutoff g = Gravitational constant NOTE The Vz value was calculated and re- corded during VSC-unit installation and checkout. e The recommended cutoff level is 100g rms with delay time of 45-75 Failtiseconds and a minlmum stor- age time of 216 milliseconds. J+60 Change No, 7+ 28 April 1970 R-3896-11 i, Verify cutoff outputs from VSC unit to irst stand electrical system for enyine cutolf, j. Verify that event recorder indicates cutoff. k. Decrease signal generator output voltage to less than 0.25 volt rms. 1, Momentarily actuate test stand VSC reset circuit, CUTOFF light goes off, and ARM hight comes on, m, Deenergize signal generator, and dis- connect signal generator and ac voltmeter from isolation amplifier. n. Reconnect accelerometer cable to isolation amplifier input connector. Momentarily depress RESET switch until CUTOFF light oes off and ARM Hght comes on. Oo. Proceed to step an, and perlorm pre- operation tap test. NOTE Steps p through am outline the pro- cedure for performing a preoperation cutolf test of the ternary VSC system. fp. Actuate power switches on isolation amplifier and cutoff unit to ON, and allow 1d minutes for temperature stabilization, q. Actuate cutoff unit DISABLE-anM switch to ARM position. ARM light comes on. r. Disconnect accelerometer eable from isolation amplifier input connector, s. Connect signal venevator and ac volt- meter (with a minimum vange of 0, 10 to 3.00 volts ring, a intnimum accuracy of 2 percent, and a minimum input impedance of one megohm) to isolation amplifier input connector, Set signal generator output frequency ai 2,000 420 cps and output voltage to less than 0,25 volt rime, Lt, Slowly increase signal generator output voltage until CUTOF? light comes on and ARM light goes off on VIBRATION SAFETY CUTOYF panel. R-3896-11 Section IJ u. Vollage reading must be within 5 per- ai. Deenergize signal generator and dis- cent of Wj value recarded on VSC-unit check connect from VSC units No. land Noa. 3, form. If this voltage reading is not as re- quired, recalibrate VSC system as outlined in aj. Connect sipnal generator to isclation J-2 Rocket Engine Ground Support Equipment amplifier input connector of VSC units No, 2 Maintenance ind Repair Manual R-3825-5, and No. 3 using a T-connector, v. Verify that no cutoff signal was supplied ak. Repeat steps ab through ac. Resalts from VSC unit to test sland electrical system, must be the same. Event recorder indicates cutoff, al, Deenergize signal generator and dis- w. Decrease signal generator voltage to connect from VSC units Mo. 2 and No, 3, less than 0,25 volt rms, , am. Reconnect accelerometer cables. CUT- x. Actuate VSC-unit RESET switch. CUT- OFF light must be off, and AIM ligh! inust be OFF light goes off, and ARM hght comes on. os Event recorder does not indicate cutoff. NOTE Steps an through aq outline the pro- cedure for performing a preoperation tay test. If more than one VSC sys- tem is used, the tap test must be per- formed on each VSC unit. y. Deenergize signal generator, and dis- conneet signal generator and ac voltnicter from isolation amplifier. 4% Repeat steps ¢ through y on remaining 2 VSC systems, Resulis must be the same. an, Connect a set of headphones to VSC unit, aa. Connect signal generator to isolation wo, Using t brass hammer, tap gently on amplifier input connector of VSC units No. 1 thrust chamber domes, An audible signal must and No. 2 using a T-connector. be received in headphones. NOTE The headphone attenuator control on the VSC unit may require ad- justment to provide an audible signal in the headphones. ab. Verify that signal generator oulput voltage is set to below 0,25 volt rms, ac. Slowly increase signal generator out- put voltage until an engine cutoff signal is re- ceived by lest stand electrical system. CUT- e The VSC set is ready for opera- OFF light comes on and ARM Hght goes off on tion at the conelugion of the tap both VIBRATION SAFE?Y CUTOFF panels, test, ‘The lap test must be per- Both event recorders indicate cutoff, formed before each static test along with the visual verification ad, Decrease signal generator output voltage of the VSC eonlrol dial settings. lo leas than 0,25 volt rms. The verniers of the timing and cutoff adjustment controls must ae. Momentarily actuate test stand V8SC be within 5 percent of their orip- reset clreuit. Both CUTORFS lights go off, and inal settings, both ARM lights come on, Both event recorders do not indicate cutoff, ap. Visually verify VSC control dial settings. Delay-time control dial musl be set at 276. af. Deenergize signal generator and dis- Storage time control dial must be set at zero. | connect from V8SC unils No, land No. 2, ag. Connect signal renerator to isolation amplilicy input connector of VSC units No, 1 aq. If VSC unit is not to be used innmediately, and No. 3 using a T-connector. move power switches on isolation amplifier and cutoff unit to OFF, ARM light gous off, ah. Repeat steps ab through ae, Results must be the same. Change No. 7 - 28 April 1970 3-61 Section III R-3896-11 Paragraphs 3.3.1.10 tu 3.3, 1.11 3.5.1.10 Thrust OK Pressure Switch Function 3.3.1.11 Imiter Harness Continuity and Insu- Test, ~——~SSS””~CS™S:SSS~SC*«éWdtHn Regs Teste CAUTION NOLS If igniter harness continuity is being If automatic checkout equipment is checked during vehicle checkout at used to test the pressure switches VAB or during launch preparation, pickup and dropout value, pressuri- omit steps a and b and check engine zation rates must be limited to 50 installed igniter harness pin-to-pin psig/see from 0-895 psig and 5 continuity concurrently with vehiclo- psig/see from 895-1,200 psig. installed igniter harness contiauity Depressurization rates must be check, limited ta 5 psig/sec from 1, 200- 895 psig, a. Disconnect igniter harness plug P4? from receptacle J47, if connected, b. Using multimeter, check that igniter a. Provide instrumentation to monitor cach harness pin-to-pin resistance does not excoed thrust OK pressure switch. one ohm. Pin list is as follows: b. Perform, as applicable, contamination and damage prevention procedures outlined in P4$7-B P4g-1h paragraph 3.14 when performing this test. P47-1 P43-bD P47-C P43-A P47-'T Pq3-C c. Slowly inercase gaseous nitrogen pres - P47-U P44-( sure (o thrust OK pressure switch connection PAl~-A P44-A to 1,240 130 psig. Record pneumatic pressure P47.) P44~1) at which cach switch actuates, P4T-k P44-13 PaAT~K P45-73 47-1 P45-D d, Slowly decrease pressure to thrust OK PA7T-M P45-C pressure switch connection to zevo, Record P4T-R P45-A pneumatic pressure al which cach switeh P4T-N P4AB-( deactuales, PAT-G P46-A V47-S P46-h P4t-~ J P46-1) e. Repeat steps c and d 2 additional times. During last 2 actuations, verify that cach switch ¢. Proceed to step ¢ if Insulation resistance actuates at 1,060 165 psig and deactuates at test is not required. 75 125 psig below actual pickup pressure. CAUTION {. Vent gaseous nilrogen pressure from An insulation resistance test must engine thrust OK pressure switch checkout not be performed if the connectors supply system, are wet, and vollage must not br applicd to interconnected contacts at the same time sinee a short f Secure instcumentation used to monitor cirewil can result in damage to the thrust OK pressure switches, equipment, d. Perform insulation resistance test of harness as follows: (1) Verify that harness connectors are dry. (2) Connect pin P47-V to connector shells P43, P44, P45, P46, and P47, 3-62 Change No, 8 - § September 1970 R-3896- 11 (3) Using megohmmeter, apply 500 vde for 5-60 seconds between each pin in connector P47 (except for pin V) and shell of connector P47. Resistance must exceed 200 megohms. (4) Using megohmmeter, apply 500 vde for 5-60 seconds netween each pin and all other pins in connector P47 except pin V. Resistance must exceed 200 megohms. &) Disconnect pin P47-V from connector Shells P43, P44, P45, P46, and P47. e. Conneet igniter harness plug P47 ta receptacle J47, if disconnected, as outlined in R- 3896-3. 3.3.2 LEAK AND FUNCTION TESTS FOR IN-. TAVLED ENGINES, (See figures 3-3 through a cedure must not be performed when propellants are in the turbopump. Refer to paragraph 3.2.3. Lforturbopump torque test procedure. 3.3.2.2 LOX Pump Seal Purge Leak and Function Test, a. Perform, ag applicable, contamination aad damage prevention procedures outlined in paragraph 3.1A when performing this test. aA. Remove protective closures from nitrogen purge and oxidizer overboard drains at thrust chamber exit. When cover !s first removed from oxidizer overboarddrain line, verify that no evidence of fluid exists. Notify Mngine Con- tractor if fluid exists. NOTE The following proecdure introduces pressure Into the turbopump LOX seal purge system. When pressure is first applied, the oxidizer over- board drain line and nitrogen purge line exlls must be observed for evidence of fluid. Notify Engine Contractor if fluld is noted. b, Turn on turbupump LOX seal purge. CAUTION Leak~teat compound used in the fol- lowing precedure must not be used on overnoard drain line exits to preclude introducing leak-test com- pound into the Hnes. # Leak-lest compound must not be used on flex line bellows since it cannot be removed from the bellows. 3.3.2.1 Turbopump Torque Test, This pro~ p Section III Paiagraphs 3.3.2 to 3.3.2.3 Procedure Result c. Apply leak-test coum- pound (MIL- 1L-25567) to ail joints and fittings of turbo- purnp LOX seal purge system. NOTE In the following procedure, if leakage is expected in excess of 4,000 scim, to flowtesters raust be connected in parallel at each line. e Step d is omitted at MTF. dad. Using Pneumatic Flow Tester G3104, or equivalent, simultaneously 18 5,000 scira measure purge s} stem from each drain flowrate at oxidizer and line. If zero nitrogen overbourd drain flow exists, lines. Record results. perform iso- lation test (paragraph 3.3.3. 1). No leakage is allowable, Maximum al- lowable leakage NOTE Step e i8 omitted at MAF and KSC. e. Verify purge flow at oxidizer and nitroyen overboard drain lines. If zero leakage exists, perform isolation test (paragraph 3.3.3, 2). f. Turn off turbopump LOX seal purge. WARNING The following procedure uses clean- ing compound, which is volatile. Use in a well-ventilated area since the vapors displace the oxygen inthe air, resulting in suffocation. g. Remove all leak-test compound from joints and fi.cings with a clean, dry cloth, or by flushing inaccessible areas with cleaning compound (MIL-C-81302), h, Remove packaging and install protective closures removed In step aA, 3.3.2.3 Cocoon Purge Leak and Function Test, a. Turn on cocoon purge. Purge pressure at MAF must be 2045 psig. Purge pressure at KSC must be within interface acceptability Umits specifled in section I, Change No, 9 - 2 December 1970 3-63 Section 1 R- 3896-11 Paragraph 3.3, 2.4 b. Verify gasecus nitrogen flow through Procedure Result cocoon purge system by audible tlow trom 7 ° ¥ manilold or by feeling supply line. bh. Pressurize heat Heat exchanger helium exchanger helium sys- system is pressurized, CAUTION tern to 200 410 psig. In the following procedure, lvak-test candd, (Deteled) | compnund must not be used or purge manitold exits to preclurle introdue- CAUTION ing leak-test compound into the manifold, Leak-test compound must not be used on flex line bellows since it Procedure Result cannot be removed from the bellows. ce. Using leak-test Fuzz leakage (as e, Apply leak~ No leakage is allowable compound (MIL-L-25567), defined in section test compound except at joints listed check all joints of II) is allowable at (MIL-1.-25567) to in step eA, ; coecon purge system for coupling nut and all flanges, fittings, leakage, flanged joints, instrumentation lines, —— and bellows in heat NOTE exchanger helium system. Step dis omitted at MAF, cA. Verify leak- Fuzz leakage (as d.) Verify by instrumentation indication age using leak=test defined in section If) that purge teraperature at engine interface is compound is allowable, within limits of seclion II. (MIL-L-25567), or equivalent, when c. Turn off cocoon purge. lenkage is suspected at the following joints: SRNING (1) Helium supply duct (heat exchanger The following, procedure uses clean- end) to heat exchanger ings compound, which is volatile, Use ina well-ventilated area since the (2) Heat exchanger to helium relarn duet Vitpors epi the oxygen in the (heat exchanger end) air, resulting in suffocation. (3) Hellum bypass hose to helium return f. Remove all leak-test compound from duct (heat exchanger end) joints and fillings with a clean, dry cloth or by flushing inaccessible areas with cleaning (4) Helium return duct (heat exchanger compound (MIL- C-8 1302). end) to helium wrap-around duct 3.3.2.4 Heat Exchanger Helium system Leak (5) Heat exchanger heltura outlet instru- Test, mentation hose to helium return duct instru- ; mentation tap HH3a (on engines not incorporating ff a. Perform, as applicable, contamination MD96 change) and daniage prevention procedures outlined in Ta paragraph 3, 4A when performing this teat. (6) Heut exchanger helium outlet instru- nA. Provide a pneumatic source of gaseous mentation hose to transducer {on engines not nitrogen (M1TL-P~27401), a mixture of gaseous incorporating MD96 change) nitrogen (MIL.-P-27401) and refrigerant, Type 12 (Federal Specification BB-F- 1421), or he- (7) Heat exchanger helium outlet tempera~ lium (Bureau of Mines, Grade A}, as specified ture transducer to helium outlet duct Instru- by requirements of section I, to heat exchanger mentation tap HH3b (on engines not incorporating § heliuin aystem. MD96 change) 3-64 Change No. & - 9 September 1970 R-3896-11 NOTE Step {is performed only at MAF, Procedure Result No lIcakage is allow- able. f, Using Halogen Leak Detector 5797934-G1 (General Electric), or equiva- lent, monitor exhaust system nianifold for preserce of refrig- erant, Type 12 (helivin coil leakage). NOTE When external pneumatic source is liclium, leak detector Uson Model 500 (Uson Corp) must be used to monitor exhaust system manifold for presence of helium. t. Depressurize heat exchar ser helium systen., h. Disconnect pneumatic system from heat exchanger heHum system. Remove pressure caps from packaging, and install pressure caps on open ports, WARNING The following procedure uses clean- tng compound, which is volatile, Use tna woll-ventilated area since the vapors displace the oxygen In the air, resulting in suffucation, i. Remove all leak-test compound from joints and fittings with a clean, dry cloth or by flushing inaccessible areas with cleaning eompound (MI.-C-81302). 3.3.2.5 Test. Heal Exchanger LOX System Leak a. Perform, as applicable, contamination and dauniage prevention procedures outlined in paragraph 3.1A when performing this test. aA. Provide a pneumatic source of gaseous nitrogen (MIL-P-27401), or a mixture of gaseous nitrogen (MIL-P-27401) and refrigerant, Type 12 (Federal Specification BB-F-1421), as Section Ili Paragraph 3.3.2.5 specified by requirements of section I, to heat exchanger oxidizer system, NOTE Steps b and ¢ ave performed only at MAL, b. Install thrust chamber throat plug (para- graph 3.6.15). Install a ground half quick- disconnect on throat plug quick-disconnect, CAUTION In the following step, the paseous nitrogen supply hose must be sup- ported lo prevent the weight on the seal valve stem from damaging the seal, bA. Connect a source of gaseous nitrogen to throat plug seal. Using a sultable material, support the gaseous nilrogeca supply hose to re- lieve @ll woight of hose from seal valve stem, Procedure Result, Thrust chamber throat plug seal is peessurized, c, Pressurize throat plug seal to 50 (45, -10) psig, Maintain pressure during remainder of teal. d. At MAF and KSC, slowly pres- surize heat exchanger LOX system to 300 110 psig, Heat exchanger LOX system is pressurized, dA, AtMTF, slowly pressurize heat exchanger LOX system ta 1,000 450 psig. Heat exchanger LOX system is pressurized, NOTE Slep c is performed only at MAF, Maximum ailowable leakage ie 60 scim. ea. Using Pneu matle Mlow Tester G3104, or equivalent, at adapter on throat plug quick-disconnect, measure and recora reverse-flow leakage past heat exchanger check valve gate. Change No. 9 - 2 December 1970 3-65 Section TI fandg. (Deleted) CAUTION Leak-test compound used in the following procedure must net be used on overboard drain line exits to preclude introducing leak-test campound into the lines, e Leak-test compound must not be used on flex line bellows since tt cannot be removed from the bellows, Procedure Result Ali MAF and KSC, no leakage is allowable except at heut ex- changer to GOX duct (heat exchanger end) joint and oxidizer by-~ pass hose to GOX duct {heat exchanger end) joint, where fuzz leak- age (as defined in section Il) ts allowable. h, Apply leak- test compound (MIL.~L-25567) to all flanges, fittings, instrumentation lines, and bellows in heat exchanger oxidizer gystem, At MTF, no leakage is allowable except at heat exchanger to GOX duct (heat exchanger end) joint, oxidizer bypass hose to GOX duct (heat exchanger end) Joint, and GOX duct (heal exchanger end) to heat exchanger GOX wrap-around duet joint, where fuzz leak- age (as defined in section II) 1s allowable. NOTE Steps i and j are performed only at MAF subsequent to engino slatic test, i, Using Halogen Leak Detector 5797934-GI (General Electric), or equiva- lent, monitor exhaust system manifold for presence of refr'g- erant, Type 12 (oxi- dizer coil leakage). No leakage {5 allowable. 3-66 Change No. 8 - 9 September 1970 R- 3896-11 j. luepressurize thrust chamber throat plug seal to zero k. Depressurize heal exchanger LOX system to zero, 1, Disconnect pneumatic system from heat exchanger LOX system. Remove pressure caps from packaging, and install pressure caps on open ports, R~-3896-11 ni. Remove thrust chamber throat plug, if q installed (paragraph 3.6.16), WARNING The following procedure uses clean- ing compound, which is volatile. Use ina well-ventllcved area since the vapors disolace the oxygen in the air, resvlting in suffocation. n. Remove ali leak-test compound fro.a joints and fittings with a clean, dry cloth or by flushing inaccessible areas with cleaning ecrapound (MIT,-C-84302), 3.3.2.6 Ignition Monitor Valve Diaphragin Leuk ‘Test, a. Perform, as applicable, contamination and damage prevention procecures outlined in paragraph 3.1A when performing this test. vA, Remove prossure cap or engine check- ist adepter $922007-11, as ae from ignition monitor valve CONTROL port quleck- disconnect, and install engine checkout valve high- pressure adapter 9022008-21, or equiva~ lent, on CONTROL port quick-disconncet, hb. Provide a gaseous nitrogen (MIL~P-27401) smirce to adapter. c. Verify that stage fuel pre- valves are closed, then vent the fuel feed system between pre-valves and engine fuel vaives during this test by removing pressure cap from, and in- stalling dvain heses on, No, 1 and No, 2 fuel high-pressure duct drain quick disconnects. d. Disconnect nition monitor valve drain tube frome ignition moni tor yalve ATMOS RETF nore, NOTE Steps dA through dC are onticnal, dA. Remove attaching hardware that secures ignition monitor valve sense tube clamp to bracket on thrust chamber fuel inlet manifold. Reiain attaching hardware for reinstaBation if acceptable for reuse Jn accordance with require- ments of sectlon If, Change No, 3 = @ Section Jif Paragraph 3.3.2.6 dB. Remove attaching hardware that secures ignition munitor valve sense tube to thrus chamber fuel inlet manifold; carefully separate flanges, and remove seal plate. Retain atlach- ing hardware for reinstallation if acceptable for reuse in accordance with requirements of section II. dC, Install pressure test fixture T-5048436, or equivalent, on thrust chamber fuel intet manifold between tenition monitor vaive sense tube flange and fuel inlet manifold flange. Torque nuts to 47-57 in-lb. Connect a red streamer to test fixture. e, Verily that engine checkout valve is in ground position, Verify that hypergol test tonl, or equivalent, ip not instailed and that bypergol cartridge installed switch is not picked up. f. Remove thrust chamber exit closure and sceurity closure or thrust chamber throat closure, If installed, g. Supply gaseous nitrogen at 1,400 +20 psig to ignition monitor valve CONTROL port. i. Using Pneumatic Flow Vester G3104, or equivalent, measure and record leakage at igni- tion monitor valve ATMOS REF port. No leak- age ia allowable. i. Decrease gaseous nitrogen supply pressure to ignifion monitor valve CONTROL port to zero, NOE The method for applying lubricant in the following precedure is outlined in R- 8895-3. j. Remove plugs, lubricate (Method A) iting and (Method G) tuhe with hubricant grease REO140-012 (Rocketdyne), and install ignition monitor valve drain tubo, Torque coupling nuls to 270-345 in~lb. k, Supply gaseuus nitrogen at 1,400 420 psig to ignition monitor valve CONTROL purt, 1. Apoly leak-test compound (MIL-L-255¢7) to all pressurized joints of ignition monitor valve, No leakage is allowable, December 1970 3-66A/3- 666 R-3898-11 m. Depressurize ignition monitor valve CONTROL port and disconnect gaseous nitrogen supply. NOTE Sieps mA through mD are required only if the ignition monitor valve sense tube was blanked off, i) 6mA. 6Verify that ignitlon monitor valve sense ¥ tube clamp is disconnected; then remove fas~ S ieners that secure ignidon monitor valve sense F tube to ihrust chamber fuel inlet manifold, and B remove blank plate fram between flanges, 4 mB. Verify allnement of ignition monitor # valve sense tube as outlined in R-3896-3, B om. Remove seal plate from packaging, and a install seal plate between ignition monitor yalve B sense tube and thrust chamber fuel inlet mani- B fold. Secure tube to manifold with 4 bolts, 8 f washers, and 4 nuts, Torque nets to 47-57 A in-Jb, f mid. Install clamp securing ignition monitor B valve sense tube to bracket on thrust chamber 2 fuel inlet manifold. Torque clamp fasteners ww 24-30 in-lb, n. Remove engine checkout valve high- pressure adapter, Remove pressure cap from packaping, and install pressure cap on ignition monitor valve CONTROL port quick-disconnect fingerticht, . WARNING The following procedure uses clean- ing compound, which is volatile. Use in a well-ventilated area since the vapors displace the oxygen in the ais, resulting in swiifocation, o. Remove all leak-test compound from joints and fiitings with a clean, diy clotk, or by Hushing inaccessible areas with cleaning compound (MIL~C~81202), Section HI Paragraph 3,3,2.7 3,3.2.7 Hypergol Manifold Leak and Function Tesi. when Mowtesters are specified In this procedure, Pneumatic Flow Tester G3104, or equivalent, must be used, a. Perform, as applicable, contamination and damage prevention precedures outlined in paragraph 3.1A when performing this test. aA. Remove pin and closure from hypergol lnanifoid cartridge confainer inlet port. Store closure ii: a clean plastie bag. Change No, 9 ~ 2 Liocember 1970 3-67 Section II WARNING The following procedure uses dry- cleaning solvent, which is flammable and must not be used near heal, sparks, or open flame. Inhalation of its vapors or prolonged contact with the liquid can cause serious injury. NOTH Tho method for applying lubricant me the following preeedure is out lrned in R-8996-3, b. Clean threads of hypergol ianifold car- fridge contamer inlet poct with drvcleaning solvent (Federal Specification P- D-680), Lubricate (Method A}threads with lubricant prcase RBOU40-012 (Rocketdyne), CAUTION When installing hypergol simulator into the hvpergol manilold cartridee eontainer inlet port, extreme care must be used te prevent dainage ta the hvpergoi rartvidge follower. a The threads of the hypergel siniulator cap raust be «lean and free of nicks, tu prevent galling the threads of the can and tmlet port, ¢. Make sure that threads of cap on hypergol I simwator T-5G¢29716, ov equivalent, are clean and free of nicks; then lubricate (Method 1) BTA] simulator shalt O-ring with F$1281 geease (Now Corning Corp), and carcfully inseri simulator into hvpergol manifold cartridge container inlet port, and serew simulator (clockwise) onto inlet port until simulator bettoms. d. Verify that pressure cap is installed on union in simulator cap, €. Connect a gaseous nitrogen supply (MIL- P-27491) to leypergol manifold draia quick-disvonnect, f. Ltemove igniter fuel valve vent drain tube, and ignition monitor valve drain tube. 3-68 Change No, 12 - 23 August 1971 R -3886-11 g. Verify that stage fuel pre-valves are Closed: then yent tuel feed system Letween pre- Valves and engine fuel valves by iastallng drain lines on No, Land No, 2 fuel high-pressuce duct quick-cisconnects. Procedure Result h, Slowly suvply Harseous nuroren at 200-30 psig lo re- verse side of igniter fed valve poppet arough hyped gus mondold drain quick-disconnect, Hypergol manifold is pressurized to 200 +10 psig, NOTE if ignitor iuel valve relieves prior to allaining, 190 psig, supply pressure must be reduced until valve reseats, since sleps { through k must be per- formed al a pressure level below valve apening pressure, Maximum allow- able leakage for each quick- disconnect is a s¢im. i. Using flow- tester, measure and record poppet reverse- flow lerkape past hypergol manifold purge quickh-dsconnects. Maxiinuin allow- abto leakage is 0.25 scim. j. Using Mowteste c, mcusure loakare past igniter fuel valve pis- ton shaft O-ring at igtiler fuel valve vent pert, k, Using Movtester, measure leakage past can follower O-ring at ATMOS REF port, leakage is 0,25 srim. Bypergol manifold I. Liecrease gaseous is depressurized. nitrogen supply pres~ sure fo zero. Mavi:ratm allowable R-3806 - 11 NOTE The method for applying {ubricant in the following procedure is out- lined in R-3896-3, m,. Remove plugs, lubricate (Method A) fit- tings and (Method G) tubes with lubricant grease RBO140-012 (Rocketdyne), and install ignition monitor vaive drain and igniter fuel valve vent drain tubes. Turque coupling nuts to 270-245 in- tb. n. Remove pressure cap from packaging, and install pressure cap on Lypergol manifold purge uick-disconnect. Torque pressure cap to 30-40 -lb. Safetywire pressuce sap with Inconel lockwire MS20#95N. Procedure oO, Slowly apply yascous nitrogen at 200 +10 psig to re- Result Hypergol manifold is pressurized to 200 +10 psig. verse side of igniter fue! valve poppet through hypergul manifold drain quick- disconnect, NOTE If igniter fuel valve relieves prior tu attaining 180 psig, supply pres- sure must be reduced until valve reseats, since step p must he per- formen at % @ pressure level below valye opening pressure, No leakage is allowable. p. Apply leak-lest eonipound (MIL-J.-25567) to all pressurized joints and ports cf hypergol manifold, q. Slowly increase Maximum igniter gpaneous niirogen pres - fuel valve relieving sure until igniter fue] pressure is 270 valve relieves or a psig. moximum of 280 psig is reached. Record relieving pressure, Hypergol manilotd is depressurized, r. Decrease gaseous nitrogen supply pres- Bure ta zero, s. Repeat steps gq and r 2 additional Umes, Section 10 Paragraph 3,3.2.8 t. Disconnect gaseous nitrogen supply from hypergol manifold drain quick-disconnect. Re- meve pressure cap froin packaging, and install pressure cap on quick-disconnect, Torque pressure cap to 30-40 ft-lb. Safetywire pres- sure cap with Incone! lockwire MS820995N, u. Remove hypergol simulator T-5029716, or equivalent, from hypergol manifold cartridge 4 container inlet port, WARNING The following procedure uses dry- cleaning solvent, which is flam- mable and must not be used near heal, sparks, or open flame, In- halation of its vapors of prolonged contact with the liquid can cause serious injury. ¥. Clean threads of hypergol manifold car- tridge container inlet porl with drycleaning solvent (Federal Specification P-D-680). w. Rernove hypergol manifold cartridge container inlet port rlosure fvorn packaging. Lubricate (Method L) closure packing with F§1281 grease (Dow Corning Corp) and install closure, Secure closure with attaching pin. WARNING fhe folowing procedure uses clean- ing compound, which ws volatile. Use ina well-ventilated areu since the vapors disp‘ace the oxygen in the air, resulting in suffocation. x. Remove all leak-test compound from joints and fittings with a clean, dry cloth or by flushing inaccessible areas with cleaning compound (MIL~C'-8 1302), 3.3.2.8 Hydraulic Control System Leak and Function Test at _MTF (Prior to Sta Static Test) and KSC. This teat contains pr ocedures for leak testing the hydraulic control system, cycling engine propellant valves, determining ignition monitor valve shuttle pressure, and testing the fgnition monitor yaive interfiow. If surface wetting is noted at any time during the test, refer to section ll to determine tf the condition is acceptable. Change No. 12 - 23 August 1971 3-69 Section I a. Verify that stage fuel pre-valves are closed; then vent the fuel feed system between pre-valves and engine fuel valves by installing drain houses on No. 1 and No. 2 fuel high- pressure duct quick- disconnects. aA. Verify that checkout valve is in ground return position, aR. Perform, as applicable, contamination and dJaniage prevention procedures outlined in peragraph 3. 1A when performing this teat. b. Attach drain hoses at quick-disconnect of the following: CAUTION In the following procedure during removal of No. land No. 2 thrust chamber fuel inlet manifold quich- disconnect pressure cap, the quick- dis-unnect body must not be allowed to turn or damage to the quick- disconnect body can result. (1) No. Ii thrust charnber fuel inlet mani- fold (2) No. 2 thrust chamber fuel inlet mani- fold (3) Engine contro) valve supply tube (4) Checkout valve engine return bose CAUTION In the following procedure, during removal of the gaa generator ball valve fuel iniet quick-diasconnect pressure cap. the quick-disconaect body must not be allowed to turn since a torque decrease between quick-disconnect body and adapter or adapter and gas gencrator bali vaive fuel housing can result in seal leakage. (5) Gas generator ball valve fuel inlet drain 3-70 Change No, 6 - 30 February 1979 R- 3896-11 bA. Remove closure from fuel overboard drain fine. bb. On center engine, remove pressure cap from actuator return line drain quick disconnect, ec. Connect an external suppiy of gascous nitrogen (MIL-P-27401), capable of being regu- lated and monitored froin G- 100 psig, to ignition monitor valve CONTROL port quick- disconnect. d, ?rovide instrumentation to monitor pro- pellant valve position indicaters (position switches and potentiometers when applicable). e, Provide instrumentation tu monitor try- draulic pressure at engine interface. NOTE Step £ is omitted at KSC. f. Install a blank plate between thrust cham- ber fuel inlet manifold and ignition monitor valve sense tube as fo!lawa: (1) Remove attaching hardware that secures ignition monitor vaive sense tube clamp to bracket on thrust chamber fuel inlet. Retain attaching hardware for reinstallation, if accept- able for reuse in accordance with requirements of section II. (2) Remove attaching harawore that secures ignition monitor valve sense tube to thrust chamber fuel inlet manifold. Carefully separate flanges and remove seal plate. Retain attaching hardware foc reinstallation, if acceptable for reuse in accordance with requirements of section i. R-3896-11 (3) Install pressure test fixture T- 5043436, or equivalent, on thrust chamber fuel inlet mani- fold betwecn ignition monitor valve sense tube flange and fuel inlet manifold Mange, Torque nuts to 47-57 in-lb, Connect a red streamer to test fixture, g. Remove pin and closure from hypergol manifold cartridge container intet port, WARNING The following procedure uses dry- cleaning solvent, which is flam- mable and must not be used near heat, sparks, or open flame. Th halation of its vapors or proionged contact with the Liquid can cause scrious injury. NOTE The method for applying lubricant in the following procedure is out- Hned in R-3808-3, h, Clean threads of hypergol manifold car- tridge container inlet port with drycleaning solvent (Federal Specification P-D-680). Lubr- cate (Method A)theeads with lubricant prcase RBO140-012 (Recketdyne}. CAUTION When insta)ling the hypergol sys- tem test tool into the hypergol manifold cartridge container inlet port, extreme care must be used to prevent damage to the hypergol cartridge follower, e The threads of the test tool cap must be clean and free of nicks to prevent galling the threads of the eap and inlet port. i. Make sure that threads of test tool capare clean and free of nicks: then lubricate (Method lL.) cap packing with S128] grcase (Dow Corning Corpjand carefully insert hypergol system test tool 9021279 or equivalent, into hypergo} mani- fold curtridge cowainer inlet port, andscrew cap (clockwise)onto inlet port until cap bottoms. Change No. 8 - 9 September 1970) Section TI 3-70A/3- 70H R-3896-11 Procedure Result Hydraulic control system is pressurized to 1,800 +50 psig. j. Slowly pres- surize engine hy- draulic control system to 1,800 +50 psig. k, Inspect all hydraulic fittings, joints, lines, and components, includ- ing instrumentation system, far leakage. NOTE In the following step, previously recorded component leakage should be used as a guide for determining component isolation scquence., When Jeakage is accounted for, no further isolation is required. If necessary, reiev to posrapraph 3,3.%.2 for isola- tion procedures, No external leakage is allowable. lL. Monitur fucl overboard drain line, at thrust chamber cxit, for fuel leskage. Any leakape requires isclation from fuel overboard drain line and recording of leakage rate of the following cunrponents: (1) Redunesat shutdown valve 2 cc/m fuel leakage maximun from drain port 5 ec/m fuel leakage maximum from drain port (2) Ignition monitor valve 5 ce/m fuel leakage maximurn from over- ride drain port (3) Engine con- tial valve (4) All other components compion to this drain system No leakage is allow- able, m, Monitor engine 2 ce/m maximem hydraulic supply check valve leakage at engine control valve supply tube drain quick-disconnect drain hese. n. Monitor check- 2 ce/m maximum out valve ball seal leakage at checkout valve engine return hose drain quick~ disconnect drain hose, o through gq. (Deleted) Section Il Procedure Result see: Hydraulic control sys- tein is pressurized to 1,550 350 psig. r. Decrease hy- draulic pressure to 1,550 :50 psig, rA. Monitor and 5 drops per minute record actuator re« maximum turn line drain quick- disconnect poppet leakuge (center en- vine only), CAUTION Engine control valve start or stop solenoid must not be actuated with a hydraulic pressure of less than 900 psig, since damage to the en- gine control valve ean occur. 8. Momentarily supply 24-30 vde to engine contro} valve start solenoid (J-18, pins n (4) and m (-) at engine interface). Gas generator ball valve and No. 1 and No, 2 oxidizer valves open, No. land No. 2 fuet fuel valves open. t. Pressurize ignition monitor valve CONTROL port with gaseous nitrogen to 50 +10 psig. u. (Deleted) v. Slowly increase Hydraulic control sys- hydraulic supply pres- iem is pressurized to sure to 1,800 :50psig. 1,800 150 psig. w. Repeat steps k through n. x. Deerease hy- Hydraulic contro) sys- draulic supply pres- tem is pressurized to sure 10 1,550 450 psig. 1,850 150 psig, CAU TION Engine control valve start or stop solenoid must not be actuated with a hydraulic pressure of Joes than 900 psig, since damuge to the en- gine control valve can occur. y. Momentarily supply 24-20 yde to engine control valve stop solenoid (J-18, pins g (+) and k (-) at engine interface), Gas generator ball valve, No, land No, 2 oxidizer valves, and No. J and No, 2 fuel valves close. Change No. 8 - 9 September 1970 3-71 Section TY R-3896- 11 %. Vent pressure from ignition monitor valve CONTROL port. NOTE Steps aa through ag are omitted at MTF prior to engine static test. Procedure aa. Morentarily pro- B vide 24-30 vde to engine control yalve start solenoid (J-18, pins n (+) and m (-) at engine interface), ab. Slowly supply gas- cous nitrogen to ignition monitor vaive CONTROL port until No, Lor No. 2 fuel valve leaves closed position. ac. Momentarily pro- W vide 24-30 vde to en- gine cantrol valve stop . solenoid (J-18, pins g (+) and K (-) ai engine interface), Result Gas generator ball vaive and No, 1 and No. 2 oxidizer valve Open, Record pneumatic supply pressure at time either fucl valve leaves closed position. Fuel valve movement must occur at 20 14 psig at ignition moniter valve CONTROL port when ignition monitor valve sense tube is blanked oft. When sense tube is net blanked off fuel valve movement must occur at 21 +4 psig, Gas generator ball valve, No. band iin, 2 oxidizer Valves, and No. 1 and No, 2 fuel valves close. ad. Vent gaseous nitrogen supply pressure from ignition monitor valve ae. Repeal steps aa through ad one additional time; then repeat steps aa and ab, and proceed to sicp af. 3-72 CONTROL port. Rach ignition moni- tor valve shuttle pressure must occur within '2 psig cf the other shuttle pressures. Change No, 6+ £0 February 1970 WARNING The following procedure energizes the redundant shutdown valve sole- nuid, which causes tie valve hous- ing to heat up. After electrical power has been applied continuously, the valve solenoid case temperaiure can cause injury to personnel lourch- ing the case. @ It the redundant shutdown valve is kept energized for more than 15 minutes, the solenoid temperature buildup will cause the valve to actuate slower. Procedure Result Gas generator ball valve, No. Land & No. 2 oxidizer valves and No, 1 and No. @ fuel valves close, af, Momentarily pro- vide 24-30 vde to redun- dant shutdown valve sole- noid WJ-18, pins DG) and L (-) at enzine interface). ag. Yent gaseous nitrogen pressure from ignition munitor valve CONTROL port, Hypergol cartridge installation is simulated, ah. Depress and hold lever on hy- pergol test tool, Gas penerator bau valve and No, 1 and No, 2 oxidizer valves open. ai. Momentarily supply 24-30 vde to engine control yaive start solennid (J+ 18, pins n (+) and m (-) af engine interface), CAUTION The following procedure pres- S irizes the ignition monitor valve CONTROL port. lf pressure in excess of 100 psig is applicd to ig- nition monitor valve CON'TROL port, damage to the valve cartridge fcl- lower can resull, aj. Slowly supply gaseous nitrogen at 28 +2 psi: to ignition monitor valve CONTROL port, Wait 5 minutes; thon verify by instrumentation indication that No. l and No. 2 fuel valves re- main closed. Rerord verification. R-3896-11 ak, Vent gaseous nitrogen supply pressure from ignition monitor valve CONTROL port, al, Release lever of hypergo) test tuol. Procedure Result am. Mamentarily Gas renerator ball supply 24-30 vde to valve and No. 1 and engine control valve No, 2 oxidizer vaives stop solenoid (J-16, close, pins g (+) and k (-) at ongine interface), an, Depressurize hydraulic control system. ao. Disconnect drain hoses from the follow- ing quick-disconnecis. Remove pressure caps from packaging, and install pressure caps on guick-disconnects, Torque pressure caps to 30-40 ft-lb. Safetywire pressure caps with inconal lockwire MS20995N, CAUTION In the following procedure, during installation of the No. 1 and Na, 2 thrust chamber fuel inlet manifold quick-disconnect pressure cap, the quick cisconnect body must sot be allowed to turn, since damage to the quick-disconnect bady can reswt. (1) No. 1 thrust chamber fucl inlet mani- fold drain (2) No. 2 thrust chamber fuel inlet mani- fold drein (3) No. J fuel high-pressure duct drain (4) No. 2 fuel high pressure duct drain (5) Engine contro! valve supply tube drain (6) Checkout valve engine return hose drain NOTE The method for appiying lubricant in the follcwing procedure is outlincd in R- 3896-3, Section Jil aoA. Remove drain hose from gas generator ball valve fuel inlet drain, lubricate (Method A) J threads of quick-disconnect with lubricant grease RBO140-012 (Rocketdyne) or F51281 grease (Dow Corning Corp). Kemove pressure caps from packaging and install pressure cap. Torque pressure cap to 210-230 in-lb. Safety- wire pressure cap with Inconel lockwire MS2G6995N. aoB. On center engine, remove pressure cap from packaging and install pressure cap on actuator return line drain quick- disconnect. Torque pressure cap to 3-40 ft-.b. Safetywire pressure cap with Inconel lockwire MS20995N. ap. Remove hypergol system test toot. WARNING The following procedure uses dry- cleaning solvent, which is flammable and must not be used near heat, sparks, or open flame. Inhalation of its vapors or prolonged contact with the liquid can cause sericus injury. aq. Clean threads uf hypergol manifold car- tridge container inlet port with drycleaning solvent (Federal Specification P-D-680). ar. Remove hypergol manifold cartridge container inlet pert closure from packaging. Julmicate (Method L) closure packing with FSi281 grease (Dow Corning Corp) and install closure, Secure closure with attaching pin. as. Verify that ignition monitor valve sense tnbe clamp is disconnected; then remave fas- teners that secure ignition monitor valve sense tube to thrust chamber fuel inlet manifold, and remove blank plate froin between flanges. at. Verify alinement of ignition monitor valve sense tube as outlined in R-3896-3, au. Remove seal plate from packaging; thea instail seal plate between ignition monitor valve sense tube and thrust chamber fuel inlet mani- fold. Secure tube to manifold with 4 bu ts, 8 washers, and 4 nuts. Torque nuts to 47-57 in-itb. Change No, 8 - 9 September 1870 3-73 Section III Paragraphs 3.3.2,.8A to 3.3.2.8B av. Install clamp securing ignition monitor verve Sense tube to bracket on thrust chamber fuel irnJet manifold, Turguo clamp fasteners to 24-30 in-Jb. $.3,2.8A Hydraulic Control System Leak and Function Test at MTF Subsequent to Static Test. This test contains nrecedures for leak-testing the closed side of che hydraulic control system, If surface wetting is noted at anylime during the test, refer to section If to determine if the con- dition is aeceplebic. a. Verify that checkout vaive is ia ground return position. aA. Perform, aS applicabie, contamination and damage prevention procedures outlined in paragrzph 3.1A when performing this test. aB. Remove pressure caps and attach drain hoses to engine conirol valve supply tube drain quick-disconnect and to checkout valve engine return hose drain quick-disconnect. aC. On center engine, remove pressure cap from actuator return line drain guick-disconnect. aD. Remove closure from fuel overboard drain line. Procedure Result Hydraulic control sys-: tem is pressurized to 1,800 +50 psig. b. Slowly pres- surize angine hydrau- lic contra: sysiem to {,800 +50 psig. c. Inspect all hy- draulic fittings, joints, lines, and components, including instrumenta- tion system, for leakage. NOTE In the following step, previously recorded component leakage should be used as a guide for determining component isolation sequence, When leakage is accounted for, no further isolation is required. If necessary, vefer te paragraph 3,3.3.2 for isola- tion procedures. No external leakage is allowable, d. Monitor fuel overboard draia linc, at f thrust chamber exli, for fuel leakage. Any leak- gage requires isolation from fuel overboard drain a line and recording of leakage rate of the follow- ing components: (1) Redundant f shutdown valve 2 ce/‘m fuel leakage maximum from drain port 3-74 Change No, 8 - 9 September 1970 R-3896-11 Procedure (2) Ignition monitor valve Result, 5 ec/m fuel leakage maxinium from drain port 5 cc/m fuel leakage maximum from over- ride drain port (3) Engine con- trol valve (4) All other components common to this drain system No leakage is allowable. e. Monitor ci- gine hydraulic supply check valve leakage at engine control valve supply tube drain quick-discon- nect drain hose. 2 co/m maximun {. Monitor check- 2 cc/m maximum out valve ball seai leakuge at checkout valve engine return hose drain quick- disconnect drain hose. g. Monitur actua- tor return line drain quick -disconnect poppet leakage (center engine only). 5 drops per minute maximum h. Depressurize hydraulic control system. i. Disconnect drain hoses from engine con- trol valve supply tube drain quick-disconnact and checkout valve engine return hose drain quick-disconnect. Reinove pressure caps from packaging, and install pressure caps on quick- disconnects. Torque pressure caps to 30-46 ft-ib. Safctywire pressure caps with Inconel iockwire MS20995N, j. On center engine, remove pressure caps from packaging, und install pressure cap on actuator return line drain quick-disconnect. Torque pressure cap to 30-40 ft-lb. Safetywire pressure cap with Incone) loc'=wire MS20895N, 3.3.2.8B Hydraulic Control System Leak and etre er care ee re ee cedures for leak-testing the closed and open sides of the hydraulic control system. If surface wetting is noted at anytiine during the test, refer to section JI to determine if the condition is acceptable. a. Verily that stege fuel pre-valves are closed; then vent the fuel feed system belween pre-valves and engine fuel valves by installing drain hoses on No. 1 and No. 2 fuel high- pressure duct drain quick-disconnects. e R-2896- 11 b. Verify that checkout valve is in ground return position. bA. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3. 1A when performing this test. v. Remove plugs from the followlng lastru- mentation taps, and allow fluid to drain. (1) On engine installed in position 101, re- move plugs from taps IF2 and PFSa-2. Usea suction pump to remove fluid from PF3a-2. (2) On engine installed in position 102, re- move plug from tap KFéd-2. (3) On engine installed in position 103, re- move plug from tap KF 7a-i. (4) On engine installed in position 104, re- move plug from tap IF2. (5) On engine installed in position 105, remove plug from tap PF3a-2. Use a suction pump to remove fMuid from PF9a- 2, d. Attach drain hoses at quick-disconnects of the following: CAUTION In the following procedure, during re- moval of the No. land No. 2 thrust chamber fuel inlet manifold quick- disconnect pressure cap, the quick-- disconnect body must not be allowed to turn, since damage to the quick- disconnect body can result. (1) No. 1 thrust chamber fuel inlet mani- fold (2) No. 2 thrust chamber fuel inlet mani- fold (3) Eagine con.roel valve supply tube (4) Checkout valve engine return hose aA. On center engine, remove pressure cap from actuator return line drain quick- disconnect, Section 1 e. Connect an external suppiy of gaseous nitrogen (MIL-P-27401), capable of being regu- lated and monitored from 0-100 psig, to ignition monitor valve CONTROL port quick-disconnect. Change No. G- 10 February 1976 3-T4A Section II f. Provide instrumentation to monitor pro~ pellant valve position indicators (position switches and potentiometers, when applicable). g. Provide instrumentation to monitor hy- draulic pressure at engine interface, h. Install a blank plate between thrust cham- ber fuel intet manifold and ignition monitor valve sense tube as follows: (1) Remove atiaching hardware that secures ignition monitor valve sense tube clamp to bracket on thrust chamber fuel inlel. Retain attaching hardware for reinstallation if accept- able for reuse in accordance with requirements of section IL. (2) Remove attaching hardware that secures ignition monitor valve sense tube to thrust chamber fuel inlet manifold, Carefully separate flanges, and remove seal plate, Retain attach- ing hardware for reinstallatton if acceptable for reuse in accordance with requirements of section II, (3) install pressure lest fixture T-5043436, or equivalent, on thrust chamber fuei inlet manifold between ignition monitor valyc sense tube flange and fuel inlet manifold {ange. Torque nuts to 47-57 in-lb, Connect a red streamer to test fixture, Procedure Result i. Slowly pres- surize engine hydrau- lic rontral system to 1,890 350 psig. Hydraulic control sys- tem is pressurizcd to 1,800 +50 psig. No external leakage is allewahle,. j. Inspect all hy- draulic fittings, joints, ines, and components, including instrumenta- tion system, for leakage. BP ok through m, (Deleted) nh. Decrease hy- Hydraulle control sys- R- 3806-11 Procedure nA, Monitor and record actuator return line drain quick- disconnect poppet leakage (center en- gine only) Result 5 drops per minute maximum CAUTION The engine control valve start or stop sotenoid must not be actuated with a hydraulic pressure of less than 900 psi, since damage to the engine control valve ean oceur. Oo. Momentarily supply 24-30 vde to engine control yalve start solenoid (J-18, pins n (+) and im (-)} at engine interface), p. Pressurize ignition monitor valve CONTROL port with gaseous nitregen to 50 +10 psig. q. Slowly in- crease hydraulic supply pressure to 1,800 150 psig, r, Inspect all hydraulic fittings, junus, lines, and components, irelud- ing instrumentation system, for leakage. s. (Deleted) t. Decrease hy- draulic supply pres- sure tu 1,550 450 psig. Gas genesator ball valve and No. 1 and No. 2 oxidizer valves open, No. Land No. 2 fuel valves open, Hydraulic control sys- tem is pressurized to 1,800 450 psig. No external leakage is allowable. llydraulie control sys- tem is pressurized to 1,550 450 psig, draulic pressure to 1,550 +50 psig. 8-743 tem is pressurized to 1,550 450 psig. Change No, 8 ~ 9 September 1970 R-3896- 11 WARNING The following procedure energizes the redundant shutdown valve sole- noid, which causes the valve housing to heat up. After electrical power has been applied continuously, the valve solenoid case temperature can cause injury to personnel touching the case. a If the redundant shutdown valve is kept energized for more Chan 15 minutes, the solenvid temperature buildup will cause the valve to actuate slower. CAUTION The engine control valve start or stop solenoid must not be actuated with a hydraulic pressure of less than 900 psig, since damage to the enpine control valve can occur. Procedure, Result u. Momentarily supply 24-80 vde to enging control valve stop solenotd (J-18, pins g (+) and k (-) and redundant valve solenvid (J-19, pins D (+) and L (-) at engine interface). Gas generator ball valve, No. 1 and No. 2 oxidizer valves, and No. 1 and No. 2 fuel valves close. v. Vent pressure from ignition monitor valve CONTROL port. w. Depressurize hydraulic control system. x. Disconnect drain hoses from the following quick-disconnects. Remove pressure cape from packaging, and install pressure caps on quick-disconnects. Torque pressure caps to 30-40 ft-lb. Safetywire pressure caps with Inconel lockwire MS20905N. CAUTION In the following procedure, during instaliation of the No. land No. 2 thrust chamber fuel inlet manifold quick-disconnect pressure cap, the quick-digconnect body must not be allowed to tur1, since damage to the quick-disconnect body can result, Section IT (1) No. i thrust chamber fuei inlet manifold drain (2) No. 2 thrust chamber fuel inlet manifold ) No. 1 fuel bigh-pressure duct drain ) No. 2 fuel high-pressure duct drain (5) Engine contro! valve supply tube drain ) Checkout valve engine return hose drain xA, On center engine, remove pressure cap from packaging and install pressure cap on acluator return line drain quick- disconnect, Torque pressure cap to 30-40 ft-lb. Safelywire pressure cap with Inconel lockwire MS20095N. y. Remove fasteners that secure ignition monitoce valve sense tube to thrust chamber fuel intet manifold, ang remove blank plate from be- tween flanges. z Verify alinement of ignition monitor valve sense tube as outlined in R- 3896-3. aa. Install seal plate between ignition monitor valve sense tube and thiust chamber fuel inlet manifold. Secure tube tu manifold with 4 bolts, 8 washers, and 4 nuts. Torque nuts to 47- 57 in~ ib, ab. Install clamp that secures ignition moni- tor valve sense tube tu bracket, on thrust cham- ber fuel inlet manifold. Torque clamp fasteners to 24-30 in-Jb. NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3. ac. Remove plugs and packings from pack- aging, and install plugs AN814-4CL and packings RN2G62-3001-0004 as follows: (1) On engine installed in position 101, Ine bricate (Method J ) packings and (Method A) threads of plugs with lubricant grease RBO140-012 (Recketdyne) and install plugs and packings in taps IF2 and PF3a-2. ‘Torque plug in tap 1F2 to 40-65 in-lb and plug ‘n tap PFOu-2 te 100 +h in-lb, Safetywire plugs with Inconel lockwire MS20995N. (2) On engine installed in position 102, lu- bricate (Method J ) packing and (Method A} threads of plug with lubricant grease RBO140-012 (Recketdyne) and install plug and packing in tap KFG6d-2. Torque plug to 49-65 in-lb, Safety- wire plug with Inconet lockwire MS20995N. (3} On engine installed in position 103, lu- bricate (Method J ) packing and (Method A) threade uf plug with lubricant grease RBO140-012 Change No, 12 - 243 August 1971 3-740 Section MI Paragraph 3.3.2.9 R- 3896-11 (Rocketdyne) and install plug and packing in tap QKF72-1, Torque plug to 40-85 in-lb. safety ~ wire plug with Inconel lockwire MS20995M. (4) On engine installed in position 104, Ju- bricate (Method J) packing and (Mctiiod A) threads of plug with lubricant prease RBO140-012 (Rocketdyne) and install plug and packing in tap IF2. Torque plug to 40-60 in-lb. Safetywire plug with Inconel tockwire MS20995N. (5) On engine installed in position 105, tu- hrieate (Method J) packing and (Method A) threads of plug with lubricent grease RBO140-012 (Rocketdyne) and install plug and packing in tap PF3a- 2. Torque plug to 10045 in-lb. Safety- wire plug with Inconel lockwire MS20995N. 3.3.2.9 Valve Timing Test. a. Perform, as applicable. contamination and damage prevention procedures outlined in paragraph 3, 1A when performing this test. aA. Verify thet stage fuel pre-valves are closed: then vent the fuel feed system between pre-valves and engine valve’ by installing drain hoses on No. land No. 2 fuel high-pressure duct quick-disconnects. b. Verify that pneumatic system is connec- ted to ignition monitor valve CONTROL port (paragraph 3.3.2, 8). Procedure. c. Slowly pres- surize engine hydrau- lic contro} system to 1,550 450 psig, and circulate hydraulic fluid for a minimum of 15 minutes before proceeding to next step. Resu't Engine hydraulic con- trol system is pres- surized, d. Provide instrumentation for recording engine propellant valve times and sequence of events, e. Momentarily supply 24-30 vde to engine control valve start solenoid (J-18, ping n (+) and m (-} at engine inter- face). {. Supply gascous nitrogen at 50 410 psig to ignition moni- tor yalve CONTROL port. 3-740 Change No. Gas generator ball valve and No. land No. 2 oxidizer valves open, No. land No. 2 fuel valves open. 12 - 23 August 1971 Pcocedure Result, g. Mormentarily supply 24-30 vde to both engine control valve stop solenoid (J-18, pins g (+) and k (-) at engine interface) and redun-~ dant shutdown valve solenoid (J-19, pins b G) and L (-) at engine interface). Verify that valve imaes meet limits and that sequence of events vecurs as listed in section I, h. Vent gaseous nitrogen pressure from ig- nitton moniter valve CONTROL port, t, Repeat steps e through h two addilional times. j. (Deleted) Kk, Repeat steps ¢ aud 1, Momentarily supply 24-30 vde to redundant shutdown valve solenoid (J-19, pins 1) (+) and L (-) at engine interface), Gas generator ball valve, No. l and No. 2 oxidizer valves, and No. Land No, 2 fuel valves close. m. Vent gaseous nitrogen pressure from ignition monitor valve CONTROL port. nh, Secure instrumentation. o. Depressurize hydraulic contro) system. p. Disconnect drain hose from Ne. i and No, 2 fue) high-pressure duct quick-disconnects. Remove pressure caps from packaging, and in- stall pressure caps on quick-disconnects, Torque pressure caps to 30-40 ft-lb. Safetywire pressure caps with Inconel lockwire MS20995N. R-3896-11 3.3.2,10 Fuel Feed System Leak Test, When flowtesters are specified, Pneumatic Flow Tester G3104, or equivalent, must be used, a. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3,1A wren performing this test. aA, If engines are horizontal, remove pro- tective closure from fuel overboard drain line at thrust chamber exit, nA-1, If engines are horizontal, remove polyethvlene bag from Y-fitting: on fuel over- board drain line and install pressure cap on Y«(itling, NOTE stens aB through @ are omitted at MTF, aB, If engines are vertical, remove poly- ethylene bag from fuel overboard drain line at thrust chamber exit. b. If engines are vertical, disconnect cross to lateral drain {ube between cross and fuel overbuard drain line Y-fitting., Install pressure cap ANS 29-16C on tvel overboard drain line, e. Remove plug from hypergol manifold instrumentation tap IF3, d. Remove fuel drain manifold cover plate und geal plate from fuel drain manifold, and install fue] seal drain manifold adapter 9020907, Torque fasteners to 43-47 In-Jdb, e. Remove plugs from INLET and PRIMARY pocts on adapter, eA. Install thrust chamber throat plug (para- graph 3.6.15), Install an open adapter with a drain hose on throat plug gulck-disconnect. Vent hose outside of thrust chamber with hose outlet pointed away from personnel, eB, Remove pin and closure from hypergol manifvld cartridge container inlet port. Section III Paragraph 3.3,2,10 WARNING The following procedure uses drycleaning solvent, which is flam- mable and must nut be used near heat, sparks, or open flame. Inhalation of its vapors or prolonged contact with the Hquid can cause sertous lijury, NOTE The method fov applylag lubricant in the following procedure is outlined in R-3806-3, eC, Ciean threads of hypergol manifold cartridge container iniet port with drycleaning solvent (Federal Specification P-D-680), Lubricate (Method A) threads with lubricant grease 11B0140-012 (Rockcidyne), CAUTION Waen Installing hypergol stimulator into the hypergol manifold cartridge container inlet pert, extreme care must be used to prevent damage to the hypergol cartrlige follower. @ The threads of the hypergol simulator cap must he clean and free of nicks, to prevent palling the threads of the cap and inlet port, eD. Make sure that threads of cap on hyper-. § gol simulator T-5029716, or equivalent, are clean and free of nieks: then lubricate (Method I} simulator shaft O-ring with FS1281 grease §— (Dow Corning Corp), and carefully insert simu- § lator into hypergol m-nifold cartridge container J inlet port. Screw simulator clockwise until it bottoms. el, Verify that pressure cap is installed on union in simulator cap. Change No, 12 - 23 August 1971 3-75 Section IT NOTE The fuel system leak test may be conducted without hydraulic pres- sure appled to the hydraulic control system. However, jn the event that propellant valve Jeakaye is excessive, apply hydrantics and reperform Jeak test. Erocedure Result No exiernal leakage is allowable in hydraulic control system, f. Supply hydraulic fluid at 1,550 250 psip to engine ground hy- draulic interface. NOTE If hy raulic pressure is not supplied to engine hydraulic control systera, it must be verified that each oxidizer valve, each fuel valve, and the gas generator ball valve are in the closed position prior to performing steps fA and © Step fA is omitted at MTF, fA, Supply gaseous nitrogen (MIJ.-P-27401) as specified in requirements of section J, at 10 1 psig to LOX feed system. zg. Supply gaseous nitrogen (MIL-P-27401) oy a mixture of gaseous nitcogen (MIL-P -27401) and vefrigerant, Type 12 (Federal Specification BB-F-1421), as specified by requirements of secticn [, at 10 41 w-4¢ to fuel feed system. NOTE Steps h through 1 are oraltted at MTF, h, Remove pressure caps from the folowing quick- disconnects: (1) No, 1 and No. 2 fuel high-pressure duct drains (2) No. J and No. 2 fuel pump inlet drains (3) Engine control valve supply tube drain {4} Checkout valve to engine return hose drain 3-76 Change No, 12 - 23 August 1971 R- 3896-11 CAUTION In the following procedure, during removal of the gas generator ball valve fuel inlet dvain quick-disconnect pressure cap, the quicx-disconnect body must not be allowed to turn, since torque decrease between guick-disconnect and adapter and adapter and gas generator ball valve fuei housing can result in geal leakage. (5) Gas generator ball valve fue! iniet drain Procedure Result Leakage at each quick- disconnect must not exceed 3 scim. i. Using flowtester, measure and record poppet reverse-flow leakage at each quick- disconnect listed in step h. NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, j. Remove pressure caps from packaging and install pressure caps on quick-disconuects listed in step h, Torque 3/8-inch pressure caps to 30-40 ft-lb and $/4-inch pressure caps to 70-75 ft-lb, On engines incoryorating MD168 change, lubricate (Method A) threads of gas generator ball valve fue] inlet drain quick- disconnect with lubricant prease RBO140-012 (Rocketdyne) or FS1281 grease (Dow Corning Corn), and install pressure cap. Torque pres~ sure cap to 210-230 in-lb, Safetywire all quick-disconnect pressure caps with Inconel lockwire MS20995N, k andl, (Deleted) R- 3896-11 CAUTION Leak-tes! compound uced in the following procedure musi not be used on overboard drain line exits, to preclude introducing teak~test compound into the lines. e Leak-test compound must aot be used on flex line bellows sinc. cannot be reniwved from the bellows, Result No Jeabage is allow- able. m, Apply Jeak- test compound (MIL- L- 25567) to all flanpes, fittings, or instrumentaUlon lines connected ty the following: (1} Now ft and No. 2 fuel inlet elbows (2) No. J and No. 2 fuel high-pressure ducts (3) Mo. 1 and No. 2 fuel valves (4) Gas generator fuel duct (5) Gas generator ball valve fuel side (6) Fuel volute Inbe feed tube (7) Igniter fuel supply tube (8) ‘Lurbopump fuel impeller balance cavity supply and return tubes (8) Kngine control valve supply tube (10) Checkout valve io engine return hose NOTES Steps n through nE are omitted at MTF, n. Using flowtesler, measure and record leakage at the following: (1) Fuel drain tube disconnected in step b No leakage past gas generator bali yalve fuel shaft seal is allowable, (2) Fuel over- beard drain line at thrust chamber exit Leakage past hearing coolant control valve poppeis must not exceed 2 scim, Section Ht Procedure (3) INLET port on adapter, (Rotate turhopump snaft to determine maximum leakage whether ro- tating or siationary.)} Result Leakcge past turbopunip fuel inlet seal must not exceed 50 scim, {4) PRIMARY port on adapter, (Rotate turbopump shalt to determine Maximum leakage whether cotating or Stationary.) Leakuge past primary fuel seal must not exceed 50 scim, Leakage past igniter fuel valve seat must not exceed 0.5 scim. (5) igniter funl valve seat leakage from instrumenta- tion tap IFS, nA. Using flowtester, measure flow at drain hose on adapter installed on thrust chamber ihroal | ‘ug and record as eumbined leakage of No, 1 and No, 2 fuel valves and No, 1 and No, 2 oxidizer valves, nB, Depressiwiize fuel feed system, nC, Using (lowtester, measure flow at drain hose on adapter iustalled on thrust chamber throat pluy and record as combined leakage of No. l and No. 2 oxidizer valves, nD, Caleulate delta flow ag cliffer- ence between flow recorded in step nA and flow recorded in step nC, Rocurd flow as combined leakage of No, 1 and No, 2 fuel valves, Combined leakage of No. land Nu, 2 fuel valves must not exceed 1S scim, nf, If hydraulic control system is not pres- surized and leakage in step nD is excessive, perform steps {, fA, and nA through iC, When hydraulic control system is pressurized, com- hined Jeakage in excess of 15 scim requires isolation of No, 1 fuel valve from No, 2 fuel valve, Maximum leakage from cither valve is 15 scim, o. Depressurize LOX feed system, Change No, 12 - 23 August 19%1 3-T6A Section OI Paragraph 3.9.2, 11 p. Depressurize hydraulic control system, if applicable, WARNING The following procedure uses cleaning compound, which is volatile. Use in a well-ventilated area since the vapors displace the oxygen in the air, resulting in suffocation, q. Remove all leak-test corapound from all joints and fittings with a clean, dry cloth, or by Hushing inaccessible areas with cleaning compound (MIL-C-81302), NOTE Steps r through t are omitted at MTF, r. Remove fuel seal drain manifold adapter from fuel drain manifold, Remove cover plate and seal plate from packaging and install fuel drain inantfold cover plate and seal plate. Torque bolts to 44-47 in-Ib, Safetywire bolts with Inconel lockwlre MS20995N, S. If engines are horizontal, install protec~ tive cover on fuel overboard drain line. Torque closure fasteners fingertight plus 1/4 turn, sA, If engines are horizontal, install a poly- ethylene bag (one gallon minimum volume) on fuel overboard drain line Y-filting (paragraph 3.6, 23,1), 8B, Jf engines are vertical, install a poly- ethylene bag (one gallon minimum volume) on fuel overboard drain line at thrust chamber exit (puragraph 3.6. 23, 3), NOTE The method for applying lubricant in the following procedure is outlined in R-33896-3, t. Remove plug and packing from packaging. Lubricate (Method J) packing and (Method A) plug with lubricant greage RBO140-012 (Rocketdyne) and install plug and packing in instrumentation tap IF3. Torque plug tu 40-65 in-lb, Safetywire plug with Inconc] lockwire MS20995N, 3-76R Change No, 12 - 23 August 1971 R-~3896-11 ue Remove hypergol simulator T-§029716, or equivalent, from hypergol manifold cartridge container inlet port. WARNING The following procedure uses drycleaning solvent, which is fiam- mable and must not he used near heat, sparks, or open flame, Inhalation of its vapors or prolonged ccntact with the liquid can cause serious injury. v. Clean threads of hypergel manifold car- tridge container inlet port with drycleaning solvent (Federal Specification P~D-680), NOTE The method for applying lubricant in the following procedure is outlined in h-3896-3, w. Remove hypergol manifold cartridge container inlet port closure from packaging. Lubricaie (Method 1) closure packing with FS$1281 grease (Dow Corning Corp). Install closure and secure with attaching pin, 3,3.2,11 LOX Feed System Leak Test. When flowtesters are specified, Pneumatic Flow Tester G3104, or equivalent, must be used, a, Perform, us applicable, contamination and damage prevention procedures outlined in paragraph 3,1A when performing this test, R-3896-11 NOTE Steps aA and b are omitted ct MTF. aA. Disconnect actuator rod seal vent tubes from GXID VENT port on No. l and No. 2 oxi- dizer valves, b, IJnstall thrust chamber throat plug (para- Yeraph 3.6.15). Install an adapter with a drain hose on throat plug quick-disconnect. Vent hose outside of thrust chamber to atmosphere. Se- cure hose with hose outlet pointed away from personnel, NOTE The LOX feed system leak test may be conducted without hydraulic pres- sure applied to the hydraulic control system. However, inthe event that propellant valve leakage is excessive, apply hydraulics and reperform test. Supply hydraulic Hydraulic control sys- fluid at 1,550 +50 psig tem is pressurized. to engine hydraulic No leakage is allow- control system. able. NOTE if hydraulic pressure is not supplied to the engine hydraulic control sys- tem at 1,550 +50 psig, it must be verified that each oxidizer valve and the gas generator ball valve are in the closed position prior to per- forming step d. d. Supply gaseous nitrogen (MIL-P-27401) or a mixture of gaseous nitrogen (MIL-P-27401) and refrigerant, Type 12 (Hederal Specification BB- F~1421), as specified in requirements of section I, at 10 +1 psig to LOX feed system. Change No. 9 - 2 December 1970 Section I Section III R-3896-11 NOTE Procedure Result { k. Using flow- Leakage past turbo- ae €- Borough ny aac -omibteda tester, measure and pump primary LOX : record maxiinum seal must not exceed leakage fram oxi- 500 scirn, Procedure Result dizer overboard drain line. (Slowly e. Using fowtester, Leakage past each rotate turbopump measure and record valve bottom rod lip shaft to determine leakage at actuator seal must not exceed maximum leakage. rod seal OXID VENT 30 scirn, whether rotating port No. 1 and NO, 2 or stationary, ) oxidizer valves. 1. Remove plug from nitrorzen overboard NOTE drain line. Reconnect nitrogen overboard drain line at thrust chamber exit. Lubricate (Method A) The method for applying lubricant in fitting and (Method G) tube with lubricant grease the following procedure is outlined RBOQ140-012 (Rocketdyne). Torque coupling nut in R-3896 -3, to 450-525 in-lb. {. Reconnect tubes removed from OXID VENT pores to No. land No. 2 oxidizer valves. Lu- mandn, (Deleted) Bbricate (Method A)fitting and (Method G) tube with lubricant grease RBO140-012 (Rocketdyne). Torque coupling nuts tu 135-185 in-lb, g. Disconnect gas generator ball valve shaft oxidizer sual vent tube at actuator housing banjo fitting. h. Using flowtester, Leakage past gas gen- measure and record erator ball valve shaft leakage from banjo oxidizer seal must fitting. not exceed 10 scim. i. Using flow- Combined leakage tester at drain hose past No. 1 and No. 2 on adapter installed oxidizer valve poppets on throat plug quick. must not exceed 56 disconnect, measure scim. Leakage in ex- combined leukage cess of 96 scim re- past No. landNo, 2 quires isolation of oxidizer valve poppeta. No. 1 oxidizer valve from No. 2 oxidizer valve. Maximuin leakage from either valve is 56 scim. j. Disconnect nitrogen overboard drain ling at thrust chamnber exit, and pressure-cap engine side with plug AN806.5C, 3-78 Change Nr, 8 - 9 September 1970 R-3996-11 CAUTION Leak-test compound used in the following procedure must not be use ' on overboard drain line exits to preclude introducing leak~test compound into the lines. # Leak-test conipound must nat be used on flex line bellows since it cannot be removed from the bellows, Procedure Result o. Using lcak- test compound (MII-1,-25567), monitor leakage at flanges, gimbal yoke bellows, fittings, and instrumentation lines on or connected to the following: No leakage is allowable, except on eagines not incorporating MD128 change where fuzz leak~ ape (as defined in section I1) is allowable between gas generator ball valve oxidizer housing and actuator cavity housing joint. (1) Oxidizer pump (2) No. land No. 2 oxidizer high-pressure ducts (3} No. land No. 2 oxidizer valves (4) Gas wenerator oxidizer feed line (5) Gas generator ball valve oxidizer side (6) Oxidizer pump inlet to oxidizer pump volute (7) Gas generator ball valve oxidizer side to actuator housing p. Depressurize LOX feed system. q. Depressurize hydraulic control system. NOTE Steps r and s are omitted at MTF. ® The method for applying lubricant in the following procedure is outlined in R-3896.-3, rt, Remove plugs, lubricate (Melhod A) fit- ting and (Method G) tube with lubricant grease RBO140-012 (Rocketdyne), and instali gas gen- erator ball valve shaft oxidizer seal vent tube at actuator housing banjo fitting. Torque coupling nut to 135-185 in-lb. Section III Paragraph 3.3.2. 12 Ss. Remove thrust chamber throat plug (para- graph 3.6.16). WARNING The following procedure uses clean- ing compound, which is volatile, Use in a well-ventilated area since the vapors displace the oxygen in the air, resulting in suffecation. t. Remove al) leak-test compound from joints and fittings with a clean, dry cloth or by flushing inaccessible areas with cleaning com- pound (MIIL-C-81302). $.3.2.12 Exhaust System Leak Test. When flowtesters arc specified In this procedure, Pneumatic Flow Tester G3104, or equivalent, must be used, a. Install turbine exhaust exit pressure test fixture (paragraph 3, 6.17), aA. Perform, as applicable, contarnination and damage prevention procedures outlined in paragraph 3.14 whon performing this test. b. Disconneet oxidizer dome purge wrap- around hose at stage purge interface, and plug hose with a suitable plug capable of mating with hose coupling nut MF818C12Y (MSFC specifi- cation), NOTE The method for applying lubricant in the following procedure is ourlined in R-- 3896-3. c. Install engine exhaust system supply adapter 9022043, ov equivalent, in gas gener- ator instrumentation tap GO2a. Lubricate (Method J ) adapter packing and (Method A) adapter union with lubricant grease RB0140-012 (Rocketdyne). ‘Torque union to $5- 80 in-lb. Change No. 9 - 2 December 1976 +79 Section Il d. Connect an external supply source of gaseous nitrogen (MIL-P-27401), capable of being regulated and monitored from 0-60 psig, to adapter installed in step c. NOTE The method for appiy?oe lubricant in the following procedure is outlined in R-3896-3, e, Install engine exhaust system monitor adapter 9025299, or equivalent, in a gas gen- erator IGNITER boss. Lubricate (Method J) adapter packing and (Method A) adapter union with lubricant yrease RB0140-012 (Rocketdyne). Torque union nut to 225-275 in-lb, f, Connect a tee to adapter installed in step e, attach a hand bleed valve to one end of tee, and close valve. Connect a 0-60 psig monitor system to other end of tee, g. Remove marmon clamp holding turbopump turbine and heat exchanger antifirex shield; then remove shield, Procedure Result h. Verify that exhaust system manifold seal at thrust chamber exit is inflated to specified pressure, Sea] must remain inflated during re- mainder of test. i. Slowly supply gascous nitrogen at 10 +1 psig to cngine exhaust system through line in- Stalled in step d. Engine exhaust system 13 pressurized as veri- filed by monitor gage. NOTE Step j is omitted at KSC. Maximum allowable leakage is 25 scim. j. Remove closure from oxidizer over- board drain line, and using flowtester, measure and record reverse-flow leakage past gas generator oxidizer purge check valve gate. 3+80 Change No. 12 - 23 August 1971 R-3896-11 Procedure Result k. Remove plugs, Leakage must not and using flowlester, exceed: measure and record leakage rates at the following static seal monitoring ports: (1) Turbine to 10 scim heat exchanger (on heat exchanger flange) (2) Heat ex- 10 scim changer to exhaust manifold (on ex- haust manifold) 1, Using flowtester at vent hose outlets, measure and record leakage from the following static seal monitoring ports: (1) Gas gener- 10 seam ator combustor ta turbine manifold in- let (on gas gencrator flange) (2) Gas gener- 10 seim ator injector to combustor CAUTION Leak-test compound used in the follow- ing procedure nust not be used on overboard drain lincs ta preclude in- troducing leak-test compound into the lines. @ Leak~test compound must not be used on flex line bellows since it cannot be removed from the bellows. No external leakage is allowable. m. Apply leak- test compound (MIL-~L-25567) to all flanges, fittings, and instrumentation lines except as listed in steps n and nA, R- 3896-11 n, Using leak-iest compound (MIL- L- 25567), leuk-test the following flanges with leakage- monitoring port plugs removed. Result No leakage is allow- able, Procedure (1) Gas gen- eratar isjector to combustor \2) Combustor to turbine manifold inlet (3) Turbine manifold cutlet to heat exchanger inlet (4) Heat ex- No leakage is allow- able, Fuzz leakage (as de- fined in section If) is allowable. Fuzz leakage (as de- changer outlet to fined in section II) is hot-gas manifold allowable. nA. Using leuk-test compound (MIL-L-25567), leak-tesl the folluwing flanges: (1) ‘Turbine manifold temperature transducer to turbine manifold instrumenta- tion tap TG4a (on en- tines nat incorporating MD176 change) (2) Cover plate to turbine manifoid instrumentation tap TG4a (on engines incuorporaring MD176 change) (3) Turbine out~ lot pressure trans-~- ducer hose to hot exchanges instru- mentation tap TCG5c CAUTION The exhaust system must be depres- surized as outlined in steps o and p, to prevent contamination of the engine. Fuzz leakage (as de- fined in section IL) is allowable. No leakage is allow- able. Fuzz leakage (as de- fined in section II) is allowahle. o, Turn off pneumatic source. vp. Depressurize Exhaust system is exhaust system by depressurized., opening hand bleed valve on JONITER buss adapter until monitor gage indi- cates zero. NOT The method for applying lubricant in the following procedure is outlined in R-3896-3. Change No, 12 - 23 August 1971 Section IN q. Remove from packaging, lubricate (Method A), and install monitoring port plugs removed in step k. (See figure 3-8.} r. Install turbopump turbine and heat ex- changer antifirex shied. Position marmon clamp coupling joints within 3 degrees of a line extending f ‘orn the center of the fuel inlet elbows through the turbopurnp aft support. Torque marnion clamp coupling joint nuts to 85-95 in- tb. s Remove monitor system from adapter in gas generator IGNITER boss. Remove hand bleed valve from adapter, and remove adapter. sA. Remove plug and washer, or gasket, as applicable, from packaging. Clean and inspect threads of plug ST3950122RKLO01 for adequate silver plating. Replace plug if silver plaling is not adequate. Install washer 651912-3 ou plug. Do not lubricate plug. Install plug in gas genera- tor igniter boss and torque to 600~640 in-ib, Safetywire 2 igniter plugs together with Inconel lockwire MS20995N. As an alternate, plug MS9015-08 with washer €21912-3 or gasket AN901-8C may be used. If washer 651912-3 is used, install plug MS9015-08 in igniter boss and torque to 150-200 in-lb, If gasket AN9Q1-8C 1s used, screw plug MS9015-08 fingertight into igniter boss. Check that gasket seats in re- cessed groove on igniter boss. Torque plug to 150-200 in-Ib. Safetywire plug with Incore) lockwire MS20995N, t. Discunnect pneumatic source from adapter in gas generator instrumentation port GO2a, and remove adapter. NOTE The method for applying lubricant in the following procedure is outlined in R- 3896-3, .. Remove plug and K-seal from packaging. Lubricate (Method A) plug threads with lubricant grease 20140-0128 (Rocketdyne), and install plug and K- seal 12100CKH4 in instrumentation tap GO2a. Torque plug to 80-30 in-lb. Safety- wire plug with Inconel lockwire MS20995N. 3-804/3- 805 R-3896-11 Section IT Paragraph 3.3.2, 13 WARNING The following procedure uses cleaning compound, which is volatile. Useina well-ventilated area since the vapors displace the oxygen in the gir, resulting in suffocation. v. Remove all leak-test compound from joints and fittings with a clean, dry cloth, ov by flush- ing inaccessible areas with cleaning compound (MIL~C- 81302). w. Remove turbine exhaust exit pressure I test fixture (paragraph 3. 6.18). 3.3.2.13 Turbopump Bearing Coolant System Leak and Function Test. a. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3 1A when performing this test. aA. Remove protective covers fram oxidizer overboard drain and nitrogen overt card drain lines. Verify that no linuid is present in covers when covers are removed. Notify Engine Con- tractor if liquid is present. b. Remove polyethylene bag, as applicable, from fuel overboard drain line at thrust cham- ber exit; then install pressure test fixture T-5039241, or equivalent, on line. bA. Connect an external supply source of gaseous nitrogen (MIL-P-27401) capable of heing regulated and monitored from 0-15 psig, to test fixture installed in step b. Chunge No. 9 - 2 December 1970 3-81 Section NI Paragraph 3.3.2. 14 c. Verify that cross-to-lateral drain tube {s removed and that a pressure cap is installed on fuel overboard drain line Y-fitting (paragraph 3.3.2, 10). dad. ‘Turn on turbopump LOX seal purge sys- tem. é, Verify gaseous nitrogen flow through purge system at exit ends of nes listed in step a. Procedure Result Fuel overboard drain line and fuel drain manifold and lines are pressurized up to bearing coolant control valve outlet port. CAUTION Leak-test compound must not be used on flex line bellows since it cannot be remnved from the bellows. f. Slowly increase Supply pressure to fuel overboard drain line to 10 41 psig. Do not exceed 15 psig. No leakage \s allow- able. g. Apply leak~test conraound (MIL-L-25567) to all fittings and joints on bearing coolant control valve outlet, turbine bearing lube feed line hose, and drain lines. h. Decrease pres- sure to fucl over- board drain line to zero, System ia depressur- ized, i. Decrease turbopump LOX sea) purge sys- tem pressure to zero. j. Install protective covers removed in step a. k. Discomect gaseous nitrogen system; then remcve pressure test fixture installedin step b. kA. If engines are horizontal, install protec- tive cover on fuel overboard drain lne at thrust chamber exit. Torque cover fasteners finger- tight plus 1/4 turn. kB. If engines are horizontal, remove pres- sure cap from fuel overboard drain line Y-fitting and install a polyethylene wag (one gallon mint- mum volume) ou ¥-fitting (paragraph 3.6.23. 1). NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, 3-82 Change No, 9 - 4 December 1970 R-3896~-1] 1, If engines are vertical, remove pressure cap from fuel overboard drain line Y-fitting, Lubricate (Method A) fitting and (Method G) tube with lubricant grease RB0140-012 (Rocketdyne) and reinstall cross-to-lateral drain tube, Torque tube coupling nuts to 1,200- 1,400 in-Ib. 1A. If engines are vertical, install a poly- ethylene bag (one gallon minimum volume) on fuel overboara drain line at thrust chamber exit (paragraph 3.6. 23.3). WARNING The following procedure uses cleaning compound, which is volatile. Use in a well-ventilated area since the vapors displace the oxygen in the air, result- ing in suffocation. m. Remove all leak-test compound from joints and fitungs with a clean, dry cloth, or by flushing inaccessible areas with cleaning com~ pound (MIL-C-81302). 3.3.2.14 Thrust Chamber Pneumatic Leak Test, When flowtlesters are specified in this procedure, Pneumatic Flow Tester G3104, or equivalent, must be used, a. Remove thrust chamber throat security closure (paragraph 3,6,14), if installed. aA, Perform, as applicable, contamination an’ damage prevention procedures outlined in paragraph 3. 1A when performing this test. b. Install thrust chamber throat plug (para- graph 3.6, 15). a c. Remove pin and closure from hypergol manifold cartridge container inlet port. WARNING The following procedure uses dry- cleaning solvent, which is flammable and must not be used near heal, sparks, or open flame, Inhalation of its vapors or prolonged contact with the Hquid can cause serious injury. NOTE The method for applying lubricant in the following procedure ts outlined in R-3896-3, d. Clean threads of hypergoi manifold car- tridge container inlet port with drycleaning solvent (Federal Specification P-D-680). Lubri- cate (Method A) threads with lubricant grease RBO140-012 (Rocketdyne). R-3896-11 CAUTION WH on installing the hypergol system test tool into the hypergol manifold cartridge container inlet port, ex- tresae Care must be used to prevent damage to the hyporgol cartridye follower. e The threads of the test tvol cap must be clean and free of nicks to prevent galling the threads of the cap and in- let port. e. Make sure that threads of test tool cap are clean and free of nicks; then lubricate (Method J) cap packing with FS1291 grease (Dow Corning Corp) and carefully insert hyper- vol system test tool 9021279, or equivalent, into hypergol manifold cartridge container inlet port, and serew cap (clockwise) onte inlet port until cap bottoms. f. Install an oxidizer-clhean adapter incorpo- rating a check valve aud a union AN815-8C in thrust chamber dome PURGE 1B port. g. Connect an external source of gaseous nitrogen (MUL-P-27401), capabie of being repu- lated and monitored from 0-100 psig and filtered through a 40-micron (or smaller) filter, to adapter of thrust chamber dome PURGE 1B port. Attach filter as close ag possible to angine attach point. h, Connect a monitor gage and bleed valve to quick~discomicct of thrust chamber throat plug. i. Connect a monitor vage and bleed valve to a Suitable instrumentation tap on heat exchanger check valve. Ci.U TION A blank plate must be installed in the stage GOX line between the engine interface and the stage oxidizer tank to prevent overpressurization of the oxidizer tank during test. j. Remove pressure caps from the following quick- disconnects: Section ff CAUTION In the following procedure, during removal of the No. land No, 2 thrust chamber fuel intet manifoid quick- disconnect pressure cap, the quick-disconnect body must not be allowed to turn or damage to the quick-chsconnect body can result. (1) No. 1 and No. 2 thrust chamber fuel in- let manifolc drains (2) Hypergol manifold drain (3) Hypergol manifold purge (4) Ignition monitor valve drain (5) No, 1 and No, 2 fuel valve purge NOTE Step k is omitted at MTF and KSC, k, Verify that oxidizer dome purge wrap- around hose is disconnected from stage Inter- face and plugged (paragraph 3,3,2. 12). 1. Disconnect prefill wrap-around hose from stage interface. CAUTION In the following step, the gaseous nitrogen supply hose must be sup- ported to prevent the weight on the seal valve stem [rom damaging the seal, 1A, Conneel a source of gaseous nitrogen to throat plug seal. Using a sultable material, support the gaseous nitrogen supply hoge to re- lieve all weight of hose from seal valve stem. Procedure Result, Thrust chamber throat plug seal is pressurized, m. Pressurize throat plug seal to 50 (+5, -10) psig. Maintain pressure during remainder of test, Change No, 13 ~ 4 April 1972 3-83 Section HI WARNING The following procedure pressurizes the thrust chamber and can he ex- tremely hazardous. All personne} niust be kept clear of the thrust chamber exit during this lest, Procedure Result Thrust chamber is pressurized. Monitor gages indicate 30 (+0, -3) psip. n, Slowly supply gaseous nitrogen at 3¢ (40, -3) psig to thrust chamber through chamber dome PURGE 1B port, Maxirnurn allowable leakage is 50 scim. oOo. Using flow- (ester, measure and record reverse- flow leakage past inert prefill check valve gate at prefill wrap-araund hoge laterface, p. Using flow- tester, measure and record poppet Leakage at each quick-disconnect must not exceed 3 1everse-flow leakage sclni. at each of the quick-~ disconnects listed in step J, NOTE Sten gq is omitted at KSC, Maximum allowable leakage is 10 scim. If leakage exceeds 10 scim, perform oxidi- zer dome purge check valve isolation leak test as outlined in paragraph 3.3.3.4. q. Remove clusure from oxidizer over- board drain line and, using flowtester, measure and record reverse-flow leakage of No, f and No. 2 oxidizer dome purge check valve gates, r, (Deleted) 3-84 Change No. 13 - 4 April 1972 R-3896-11 CAUTION Leak-test compound used in the following procedure must not be used on overboard drain line exits to preclude introducing 1 ak-test compound into the lines. @ Feak-test compound must not be used or flex li1e bellows since it cannot be removed from the bellows. Procedure Result 8. Apply leak- No leakage Is allowable. test compound (MIL-L-25567) to all flanges, fittings, and connections on or connected to the following: (Record results, ) {1} Oxidlzer valves and fuel valves (duwn- stream of poppets) (2) Ignitlon monitor valve sense tube (3) Hypergol manifold outlet hose (4) Joints between thrust chamber dome and Injector ai:d belween injector and thrust chamber body (4) No. 1 and No, 2 oxidizer dome purge check valves (6) Thrust chamber dome and gas generator oxidizer purge tubes (7) Externally exposed thrust chamber tube surfaces (8) Thrust chamber dome purge ports PURGE 14, PURGE 2A, PURGE 2B, NO. 3 PURGE, and NO. 4 PURGE R- 3896-11 Section HI CAUTION Procedure Result The thrust chamber must be depres- uC, Turn off Supply pressure lo surized as outlined in steps t through thrust chamber thrust chaniher de- u to prevent contaminatton of the pressure pneumatic creases to zero, and engine oxidizer system, source, raonitor gage on thrust chamber throat plug NOTE quick-disconnect indicates zero, Steps t through uA are perfermed only at KSC, H {. Quen hand bleed valve on quick-disconnect of thrust chamber throat plug until pressure y starts venting. Procedure Result AU. Slowly depres- Thrust chamber pres- surize thrust chamber = sure decreases to A to 10 +41 psig; then 1041 psig as indicated close hand bleed valve on rmonitor gage. on quick-disconnect of thrust chamber f throat plug as supply pressure is adjusted to maintain pressure fas indicated on monitor p gage. A UA, «Apply leak- No leakage is allow. test compount’ able. (MI L- L-25567) to a internal thrust A Chamber tube § surfaces between R throat plug and exit manifold, CAU11ON The thrust chamber must be de~ pressurized as outlined in steps uB through v to prevent contamination of the engine oxidizer system. f ub. Completely Thrust chamber pres- g open hand bleed valve — sure vents. fo on quick-disconnect A of thrust chamber S throat plug, Change No, 9 ~ 2 December 19°70 3-84A/3-84B R~ 3896-11 Procedure Result ¥. Slowly open hand bleed valve on instrumentation tap of heat exchanger oxidizer supply hose, Heat exchanger oxi- dizer sysiem is de- pressurized, w. Remove monitor sage and hand bleed valve from heat exchanger check vaive. NOTE The method for applying lubricant in the following procedure is outlined in R- 3596-23. wA,. Remove from packaping, lubricate (Method A) plug threads with lubricant grease RBO140-012 (Rocketdyn2), and install plug and K~-Seal 12t00CR4 in instrumentation tap on heat exchanger check valve, Torque plug to 180 40 in-lu, Safelywire plug with Inconel lockwire MS20999N, xX, Remove monitor gage and hand bleed valve from quick-disconnect of thrust chamber throat lug. y. Remove source of gascous nitrogen and adapter from thrust chamber come PURGE 1B port, Lubricate (Method A) piug with lubricant grease RBO140-012 (Rocketdyne) and (Method R) Seal with lubricant grease RE 9140-012 (Rocketdyne) or fluorinated o11 Krytox 143AZ (Du Pont) and install plig and seal. Torque to 350 115 in-lh, and record plug instalation torque value. Safetywire plag with Inconel lockwire MS20995N. z. Depressurize thrust «hamber throat plug seal, aa. Remove thrust charaher throat plug Wl (paragraph 3.6. 16). CAUTION In the following procedure during in- Stallation of the No. land No. 2 thrust chamber fuel inlet manifold guick- disconnect pressure cap, the quick-disconnect hody must not be allowed to turn or damage to the guick-disconnect boay can result. ab. Remove pressure caps from packaging, and install pressure caps on quick-«liasconnects listed in step j. Torque pressure caps to 30-40 ft-ih. Safetywive pressure caps with Inconel lockwire MS20S95N, Section UI Paragraph 3,3,2. 18 ac. Install thrust chamber throat security closure (paragraph 3, 6. 13). ad. Remove plug from oxidizer dome purge wrap-around hose, and connect hose to stage purge interface. Use customer criteria for in- stallation data and four leak test of connection. ae. Connect prefill wrap-around hoce to stage prefill interface. Use customer criteria for in- Stallation data and for leak-test of the connec- tion, af. Remove pin that secures hypergal test tool cap, and carefully unscrew cap and remove tool from manifolrt. WARNING The following procedure uses dry- cleaning solvent, which is flammable and must not be used near heat, sparks, or open flame. Inhalation of its vapors or prolonged contact with the liquid can cause serious injury. ag. Clean threads of hypergol manifold car- tridge container inlet port with dry-cleaning salvent (Federal Specification P-D- 680), ah. Remove hypergol manifotd cartridge container inlet port closure from pachaging. Lubricate (Method 1) closure packing with F51281 grease (Dow Corning Corp) aid install closure. Secure with attaching pin. WARNING The following procedure uses clean- ng coinpound, which is vulatile. Use in a well-ventilated areca since the vapors displace the oxygen in the air, resuiting in suffocation, ai. Remove all leak-test compound from joints and fittings with a clean, dry cloth, or by flushing inaccessible areas with cleaning com- pound (MIL-C- 81302). a. Remove thrust chamber throat security closure (paragraph 3. 6. 14), | b. Supviy gaseous nitrogen (MIL-P-27401) at 40 +5 paig te prefiil fluid stage interface. Change Nu. 9 - 2 December 1970 3-85 Section IIT Paragraphs 2.3.2.16 to 3,3.2,17 c. Verify gaseous nitrogen flow through pre- fill check valve by feeling prefill lines, or audibly from thrust chamber exit. If there is no flow through check valve, perform prefill check valve isolation test (paragraph 3.3.3.3). Procedure Result d. Using leak- test compound (MIL-L-25567), check all joints of the prefill supply system for leakage. No external leakage is allowable. e. Decrease nitrogen supply pressure to Zero. WARNING The following procedure uses clean-- ing compound, which is volatile. Use ma well-ventilated area since the yapors displace the oxygen in the air, resulting in suffocation. f. Remove all leak-test compound from joints and fittings with a clean, dry cloth, or by flushing inaccessible areas with cleaning com- pound (MIL-C-81302). g. Reinstall thrust chamber throat security | closure (paragraph 3.6. 13). 3,3,2.16 LOX Dome and Gas Generator LOX A NE AE A I ll SO A injector Purge Leak and Function Test. a Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3. 1A when performing this teat. aA. Remove plug from either gas generator igniter boss. b. Make sure that thrust chambey exit is clear. c. Turn on operational low-level LOX dome and gas generator LOX injector purge. d. Verify gaseous nitrogen flow through sys- tem af gas generator igniter port and thrust chamber injector, e, Verify that purge bypass fixed orifice ia not plugged by checking for free flow of gaseous nitrogen through oxidizer overboard drain line. 3-86 Change No, 9 = 2 December 1970 R-3896-11 CAUTION Leak-test compound used in the follow- ing procedure must not be used on overboard drain line exits to pre- clude entry of leak-test compound into the line. Procedure Result f, Apply leak-test compound (MIL-L-25667) to all joints and fittings of LOX dome and gas generator LOX injector purge system. No external leakage is allowable. g. Turn off operational low-level LOX dome and gas generator LOX injector purge. WARNING The following procedure uses clean- ing compound, which is volatile. Use in a well-ventilated arca since the vapors displace the oxygen in the air, resulting in suffocation. h. Remove ali leak-test compound from joints and fittings with a clean, dry cloth, or by tlushing inaccessible areas with cleaning compound (MIL-C-81302), i. Remove plug and washer, or gasket, as applicable, from packaging. Clean and inspect threads of plug 5T3950122RKL001 for adequate Silver plating. Replace plug if not present. In- stall washer 651912-3 on piug. Do not lubricate plug. Install plug in gas generator igniter boss and torque to 600-650 in-lb. Safetywire 2 ig- niter plugs tugether with Inconel lockwire MS20995N. As an alternate, plug MS9015-08 with washer 651912-3 or gasket AN9O1-8C may be used. If washer 651912-3 is used, install plug MS89015-08 in igniter bossa end torque to 150-200 in-lb. If gasket AN901-6C is used, screw plug MS9015-08 fingertight into igniter boss. Check that gasket seats in recessed groove on igniter boss. Torque plug to 156-200 in-lb. Safetywire plug with Inconel lockwire MS20995N. 3.3.2.17 Thrust Chamber Liquid Leak Test. a. If engine environmental cover Is inatalicd, untie rope that secures exit end of cover, and turn up end secure end of cover, R-3896- 11 aA. Perform, as apnricable, comtamination and damage prevention pv. tedures outlined in paragraph 3. 1A when perfo,ming this test. b. Remove thrust chain: r throat security j closure (paragraph 3. 6. 14}. NOTE Step ¢ mav be omitted if the stage pre- valves are to be open and the fue] tank is to he pressurized a min- imum of 2 psig during this procedure. ec. Remove pressure cap from, and attach a drain line to, drain quick- disconnects on No. 1 and No. 2 fue) high-pressure ducts. CAUTION In the folowing procedures, drain line must be monitored. If drainage is observed from either line, the source of fluid must be determined hefore proceeding. d. Counect thrust chamber fucl jacket purge system to each fuel valve. ec. Make sure that thrust chamber exit mani- fold drain plugs are in closed position. WARNING The following procedure may use tri- chloroethylene, which is a loxie sol- vent, Inhalation of its vapors or prolonged contact with =he liguid can cause serious injury or death. CAUTIOD In the following procedure, during removal of the No. land No. 2 thrust charnber fuel in.et manifold quick-disconnect pressure caps, the quick-disconnee! body must not be allowed to turn since camage to the quick- disconnect body can result. NOTE Step f is omitted if ethylene glycol RBOZ10-017 (Rocketdyne) is used as the leak-test solution. Section I f. Remove pressure cap from, and connect a source of trichloroethylene, meeting require- ments of section I], or deionized water, to each thrust chamber fuel inlet manifold quick- disconnect. NOTE Step g may be omitted if the stage pre- valves are open and the LOX and fuel tanks pressurized a mini- mum of 2 psig. g. Pressurize hydraulic control system to 1, 550 +50 psig, h. Pressurize operational low-level LOX dome and gas generator LOX injector purge system. WARNING If trachloroethylene is used in the fol- Jowing procedure, inhalation of its vapors or prolonged contact with the liquid must be avoided, since it is a coxic solvent and can cause serious injury or death. i. Fill thrust chamber to injector overflow with trichlorocthylene or ethylene glycol, mect- ing requirements of section II, or deionized water, a8 applicable, to injector overflow; When turn off prefill system. j. Turn off operational low-level LOX dome and gas generator LOX injector purge system. k, Visually inspect thrust chamber tubes for evidence of fluid leakage. Mark and record lo- cntion of any leakage, J. Remove lockwire from thrust chamber exit manifold drain plugs, and install drain tools from Fue) Drainage Kit G2037 at drain plug using gasket RD262-3001-0010 between tool and drain plug adapter. Check that drain tuol extension hex wrench is extended outward when installing tool. and drain ports of tool are positioned aft. Torque drain tool to 36-60 in-Ib. m. Jeustall drain hoses on tools. Change No, 9 - 2 December 1970 3-87 Section DI Paragraph 3,3. 2, 18 n. Open drain plugs by inserting drain tool extension hex wrench into head of drain plug and rotating wrench counterclockwise. o. Turn on operational high-level LOX dome and gas generator LOX injector purge system, and audibly verify purge operaticn at thrust chamber exit. p. Pressurize thrust chamber fuel jacket purge system and verify operation of purge by monitoring emission of vapor from thrust cham- ber. q. Allow thrust chamber fuel jacket purge to flow for a minimum of 3 minutes and to continue until all vapors cease to be emitted from thrust chamber. r. Depressurize thrust chamber fuel jacket purge system. s. Turn off operational high-level LOX dome and gas generator LOX injector purge system. Depressirige hydraiwic control system, if BP apbricabte: ¥ : ay ae CAUTION In the following procedure, during in- a stallation of pressure caps on guick~ disconnects, the quick-disconnect vody must not be -llowed to turn, or damage to the boty can resull, NOTE Step u is omitted if ethylene glycol was used as the leak-teat fluid. u. Disconnect prefill system from No. 1 and No. 2 thrust chamber fuel inlet manifold quick~ A disconnects. Remove pressure caps from ® packaging and install pressure cep on each quick-disconnect. Torque pressure caps to § 30-40 fl-lh. Safetywire pressure caps with Inconel lockwire MS20895N. v. Remove drain tools. w. Remove drain plugs, and reinstall them using new K-seals 12100AA3. Torque drain pluga to 8-12 ft-lb. Safetywire plugs with Inconel lockwire MS20995N. x. Disconnect pneumatic source from fuel jacket purge quick-disconnect on each fuel valve. Remove pressure caps from packaging, and install pressure cap on each quick- disconnect. Torque pressure caps ‘o 30-40 ft-lb. Safetywire preentice caps with Inconel lockwire MS20995 5-88 Change No. 6 ~ 10 February 1970 R-3896-11 NOTE Step y may be omitted if stage pre- valves were open and fue] tank was pressurized, y. Disconnect drain hose from, and install pressure cap on, each fuel high-pressure duct quick-disconnect. Torque pressure caps to 30-40 ft-lb. Safetywire pressure caps with Inconel lockwire MS20995){. z J>rain ignition monitor valve sense Jine (paragraph 3. 5,9). a. Verify that hypergol system test teol 9021279, or equivalent, is not installed in hyper- go: manifold cartridge container port. F b. Verify that gaseous nitrogen system is not connected tc ignition monitor valve CON- TROL port. ec. Provide instrumentaticn to monitor pro- pellant valve position indicators (position switches anc potentiometers when applicable), NOTE Sten d may be omitted if test is being performed before completion of LOX do:ne and gas generator LOX injector flush. 3. Tutn on operational low-level LOX dome and gas generator LOX injector purge. Procedure Result Hydraulic control system is pres- surized to 1, 500 +50 psig. CAUTION The engine control valve start or stop solenoid must not be actuated with a hydraulic pressure of less than 900 psig, since damage to the engine control valve can occur. e. Slowly pressurize engine hydraulic control system to 1, 500 +50 psig, Momentarily sup- ay a4. 30) vde to engine control valva start sole- noid (J-38, ping n (+) and mn (-) at engine interface). Gas generatorhall valve and No. 1 and No. 2 oxidizer valves open. R-3896-11 Section lil Paragraphs 3.3.3 to 3.3.3.1 Procedure Result, aA. Perform, as applicable. contamination aad damaye prevention procedures outlined in | q 6. Verify by fuel Fuel valve closed paragraph 3. 1A when performing this test. W Valve position switch position switches 3 sued Ls Are a are ance bh. If leakage is not experienced from hoth l fuel-valves pemain position switches sides of turbopump intermediate seal, decrease a closed. must not come on. turbopump LOX seal purge pressure to zero, ‘ and backilow the turbopuinp intermediate seal CAUTION from LOX side as fallows: The engine control vaive start or {1) Disconnect oxidizer seal vent tube from slop solenoid must not be actuated oxidizer dr2zin tube. Loosen tube clamps, as with a hydraulic pressure of less required to gain aceess to oxidizer drain tube. than 900 psig, since damage to the engine control valve can oveut. CAUTION h. Momentarily Gas generator ball In the following procedure, the pres- supply 24-30 vde to valve and No. Land surization supply line must not be engine control yalve No. 2 oxidizer attached to the oxidizer overboard B stop solenoid (J-18, valves close. drain tube at the thrust chamber exit. ping g (+) and k (-) Bat engine interface). {2) Comect a gaseous nitrogen supply (MiL-P-27401) to oxidizer drain tube. (Do not NOTE attach supply line to drain tube al thrust cham- ber exit.) Step i may be omitted if test is being performed before coinpletion of LOX dome and gas generator LOX injector flush. i. Turn oft operational low-level LOX dome and gas generator LOX injector pucge. j. Depressurize hydraulic control system. 3.3.3 ISOLATION TESTS FOR INSTALLED ENGINES aa 3.3.3.1 LOX Pump Seal Isolation Test. This test is required only in the event fiow past the turbopump intermediate seal is zero. This test determines if the purge supply or the system overboard drain lines are obstructed. “Zero flow of the seal is acceptable. a, With turbopump LOX pump seal purge sys- tem pressurized, rotate turbopump shaft approx- imately 2 revolutions and repeat leakage meas- urement at overboard drain lines. If leakage is within limits, continue test (paragraph 3.3.2.2). Change No. 6 - 10 February 1970 3-88A/3-88B R-3896-11 (3) Disconnect turbopump LOX seal purge at interface. (4) Supply gaseous nitrogen at 10 +1 psig to LOX propellant feed system. (5) Supply gaseous nitrogen al 6 +1 psig to oxidizer drain tube, and backflow turbopump in- termadiate seal from LOX side, allowing flow to go overboard through nitrogen purge over- board drain tube and turbopump LOX seal purge interface. (6) Verify flow from turbopump LOX seal purge interface and nitrogen overboard drain tube. (7) Vent gaseous nitrogen pressure from oxidizer drain tube and from LOX propellant feed system. (8) Disconnect gaseous nitrogen supply from oxidizer drain tube. NOTE The method for applying lubricant in the following procedure is outlined jn R-3896-3. (9) Remove packaging from oxidizer seal vent tube. Lubricate (Method A)threads of oxi- dizer drain tube and (Method G) oxidizer seal vent tube with lubricant grease RBO140-012 (Rocketdyne), and install oxidizer seal vent tube. Torque tube coupling nut to 1, 500-1, 800 in-lb. Sccure clamp, as required. (10) Reconnect turbopump LOX seal purge at stage interface. for installation data and for leak test of the cun- nection. (11) Verify leakaye from both sides of turbo- pump intermediate seal (paragraph 3.3.2.2), 3.3.3.2 Fuel Overbuard Drain Line Isolation Test, This test is required only in event of ex- cessive leakage from fuel overboard drain line. Procedure Result a. Depressurize hydi aulie control system lo zero. tem is depressurized. Use Stage Contractor criteria Hydraulic control sys- Section III Paragraph 3.3.3.2 Procedure Result Ignition monitor valve CONTROL port is depressurized. b. Depressurize ignition monitor valve CONTROL port. bA. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3.1A when performing this test. c. Remove redundant shutdown vaive override line from between redundant shutdown valve and engine control valve as follows: (1) Remove attaching hardware that secures line to redundant shutdown valve, and remove seal plate. (Refer to R- 3896-3 for handling in« formation, ) Retain attaching hardware for rein- Stallation, if acceptable for reuse in accordance with section H, NOTE The tiethod for applying lubricant in the following procedure is outlined in R- 3096-3, (2) Install pressure test fixture T- 5041521 on redundant shutdown valve OUT port. Lubri- cate (Method J ) fixture O-ring with lubricant grease RBO0140-012 (Rocketdyne). Tcrque fas- teners to 85-95 in-1b. (3) Disconnect Jine from engine control valve OVERRIDE port. NOTE Line may be left clamped to engine. d. Remove control valve override drain tube from between tee and redundant shutdown valve DRAIN port. e. Disconnect ignition monitor valve drain tube from iynitiun monitor valve ATMOS REF port. f. Slowly pressur- ize ignition manitor valve CONTROL port to 50 45 psig. Ignition monitor valve CONTROL port is pressurized. Change No. 8 ~ 9 September 1970 3-89 Section Jl Procedure yv. Slowly in- crease hydraulic control system pres~ sure to 1,550 150 psig. Maintain this pres- sure for 5 minutes minimum while performing step h. R-3896-11 Result Hydraulic control system is pressur- ized, h. Monitor and record hydraulic fluid leak age at the foliowing ports: (1) Ignition monitor valve ATMOS RUF (2) Engine con- trol valve OVER- RIDE (3) Redundant shutdown valve DRAIN 5 cc/m maximum 5 ec/m maximum 2 cc/m maximum i. Verify that hydraulic fluid has circulated for a mininium of 15 minutes to remove en- trapped air from hydraulic control system be- fore proceeding with test, j. Momentarily supply 24-30 vde to engine control valve start solenoid (J-18, ing n(¥) and m(-) at engine interface}. k. Repeat steph. 1. Slowly increase hydraulic control sys~ tem pressure to 1,800 450 psig. m. Repeat step h. n. Slowly decrease hydraulic control sys-- {om pressure lo 1,550 450 psig. Gas generator ball valve, No. tf and No. 2 oxidizer valves, and Wo. 1 and No. 2 fuel valves open. As specified in steph, Hydraulic control systein pressure is increased. As specifiedin steph. Hydraulic control system pressure decreases and stabilizes. WARNING The following procedure energizes the redundant shutdown valye sole- noid, which causes the valve housing to heat up. After electrical power has been applied continuously, the valve solenoid cause teroperature can cause injury to personnel touching the case. 3-90 Change No, 8 ~ 9 September 1970 CAUTION If the redundant shutdown valve is Kept energized for more than 15 min- utes, the solenoid temperature buildup will cause the valve to actu- ate slower. Procedure Result Redundant shutdown valve is cnergized. 0. Supply 24-30 vde to redundant shutdown valve solenoid (J-19, pins D(+) and L(-) at engine interface). Leakage past drain port seal must not exceed 2 cc/r. p. After hydraulic system has been pres- surized for 2 minutes minimum, monitor and record fluid leak- age at redundant shut - down DRAIN port. q. Deenergize redundant shutdown valve solenoid. r. Supply 24-30 vde to engine conirol valve stop solenoid (J-18, pins g (+) and k (-) at engine interface) and monitor OVERRIDE port for leakage; then deenergize slop solenoid, Redundant shutdown RIDE port must not execed 5 cu/m, Hydraulic control system is dopres- surized, 6. Depressurize hydraulic control sys- tem te zero. t. Depressurize Ignition monitor ignition monitor valve CONTROL port to zero, is depressurized, NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, u, Remove plugs, lubricate (Method A) fit- tings and (Method G) tube with labricant grease RB0140-012 (Rocketdyne), and install control valve override drain tube between tee and re- dundant shutdown valve DRAIN port. Torque tube coupling nuls to 135-185 in-Jb. valve is deenergized. Leakage past OVER- valve CONTROL port R-3896-11 vy. Remove pressure test fixture T-5041521; then install redundant shutdown valve override. line as follows: (1) Remove seal plate from packaging, and install seal plate between line flange and redun-- dant shutcown valve OUT port. Secure line to vaive with 4 bolts and washers. Torque bolts to 85-95 in-Ib, Sefetywire bolts with Inconel lockwire MS20995N, (2) Connect line to engine control valve OVERRIDE port. Torque coupling nut. During last 1/2 turn prior to seating flare, record max- imum terque. Torque must be 50-200 in-Ib. Continue to torque coupling nut to 270-340 in-lb above recorded torque. Procedure w. Increase hy- draulic control systera pressure to 1,550 +50 ig, Pete WARNING The following procedure energizes the redundant shutdown valve solenoid, which causes the valve housing to heat up. After electrical power has heen applied continuously, ihe vaive sole- noid case temporature can cause injury to personnel touching the case. GAUTION If the redundant shutdown valve is kept energized for more thar 15 minutes, the solenoid temperatura buildup wil) cause the valve to actuate slower. Regult Hydraulic control system pressure is increased, xX. Supply 24-30 vde to redundant shutdown valee solenoid (J-19, plas DG)and L(-) at en- gine interface). Enginu control valve override port is pressurized, y.» Monitor recun- dant shutdown valve overeble line connec- tion tor leakage. No ieakage is allow- able. Hydraulic control system oressure is increased, 4% Increase hy- dranlic contro) system pressure to 1,800 +60 pale. aa. Repeat step y. As specified hi step y. ah. Decrease hy- draulic control system pressure to 1,500 «40 psift, Rydraulic contral system pressure de- creases and stabilizes, Section HT Paragraph 3.3,3.3 CAUTION The following procedure deencrgizes he redundant shutdown valve which will cause approximately 25 cc of hy- draulic fluid to be expelled from the fuel overboard drain line. Personnel must be kept clear of the fuel over- board drain line. ac. Deenergize redundant shutdown valve solenoid. NOTE The method for applying lubricant in the following procedure is outlined in R- 3896-3, ; ad, scemuve plugs, lubricate (Method A) Ht- ting and (Method G) tube with lubricant grease RBO0140-012 (Rocketdyne), and instal! ignition monitor valve drain tube. T'orque coupling nut to 270-345 in-lb. 3,3,3.3 Prefill Check Valve Isorstion Test. This test Ts required only in the event that flow through the prefill check valve is zero during leak and function testing when the supply pres- sure from the stage is interconnected to all engines. a. Derreage pressure to prefill fluid engine interface to zero, aA, Perform, as applicable, contamination and damage prevention procedures outlined in peragraph 3.14 when performing this test. b. Disconnect thrust chamber jacket prefill line from stage interface; then remnava prefill line from engine as outlined in R-3996-3, ce. Instail inlet port half of pressure test fix- ture T-5G637801, d. Connect a source of gaseous nitrogen (MIL-P-27401) te pressure test fixture £-5037801. e. Slowly supply gaseous nitrogen pressure to prefill check valve inlet gt 15 (+5, -0) psig. {f. Verity flow through check valve al thrust chamber exit by audible indication av by feeling supply line. g. Decrease gupply pressure to chech valve inict to “erg, disconnect supply, and reraove pressure test fixture from prefill check valve inet, h. Absence of flow through prefill check vaive requires replacement of prefill check valve. If flow through prefill check valve is verified, re- install thrust chamber jacket prefill line on en- gine aa outlined in R-3896-3. Connect thrust chargher jacket preflll line to stege interface, using Stage Contractor criteria for ingstaliation data and leak test of the connection, then repeat leak test of ling joints (paragraph 4.3.2. 15). Change No. 11 - 6 May 1971 3-90A/4-90B R~3896-11 AO tect aie SA ememmerrern @ Isolation Leak Test. 4 «a. Perform, as applicable, contamination A and damage prevention procedures outlined in f paragraph 3.1A when performing this test. h bb. Remove clamp that secures No. 2 oxidizer # dome purge line to support bracket. Retain @ attaching hardware for reinstallation, if accept- # able for reuse in accordance with requirements 4 outlined in section JI. c. Remove attaching hardware that secures No. 2 oxidiver dome purge line to No. 2 oxidi- q zer dome purge check valve, and carefully B remove orifice plate. Re ain attaching hard- # ware for reinstallation, if acceptable for reuse } in accordance with requirements of section I. Procedure Result Maximum allowable leakage is 10 scim. d. Using Pneumatic 1 Flow Tester G3104, measure reverse-flow leakage of No. 2 oxi- s dizer dome purge f check valve at check B valve to line ‘nterface. 4 6h ew «If leakage in step d is more than 10 scim, 4 replace No. 2 oxidizer dome purge check valve ; us outlined in R-3#96-3, {f. Subtract teakage obtained in step d for y No. 2 oxidizer dome purge check valve gate f from leakage obtained in thrust chamber pneu- B matic leak test (paragraph 3.3.2.14, step q) g to obtain leakage for Nn. 1 oxidizer dome purge check valve gate. If leakage of No. 1 oxidizer A dome purge chock valve gate is nore than 10 g scim, replace No. 1 oxidizer dome purge check A valve gate as outlined in R~3896-3. g. Remove packaging and install No. 2 oxi- RE dizer valve dame purge line as follows: (1) Vertfy alinement of line as outlined in R-9896-3. Section I Paragraph 3.3.3.4 (2) Install same orifice plate as removed between line and oxidizer dome purge check valve. Secure line to valve with 4 bolts and washers. Torque bolts to 33-39 in-lb. Safety- wire bolts with Inconel lockwire MS20995N. h. Continue test in paragraph 3.3.2. 14. Change No. 11 - 6 May 1971 3-9t Section Il R- 8896-11 Paragraphs 3.4 to 3,5, 1 3,4 STORAGE PREPARATION, 3.4.1 Storage preparation activities specified in section ], when complemented by criteria referenced in section lI, require no additional instructions: therefore, no recommendations are provided for the method of accomplishing storage preparation activities. 3.5 SERVICING. 3.5.1 LOX DOME AND GAS GENERATOR LOZ INJECTOR FLUSH, This procedure contains instructions for flushing the thrust chamber oxidizer dome and gas generator oxidizer in- jector. NOTE When performing this procedure with the engine environmental cover in- stalled, the rope that secures the exit end of the cover must be untied and the end of the cover turned up and se- cured to prevent trichloroethylene from accumulating in the cover. At the completion of the procedure, the cover must be lowered and se- cured in accordance with paragraph 3. 6. 5. e In steps reauiring hose coupling torques in excess of torque required for fittings, fittings must be head to avoid overtorquing. a. Perform, as applicable, contamination and dantage prevention procedures outiined in paragraph 3. 1A when performing this test. aA. Remove pin and closure from hypergol manifold cartridge container inlet port. WARNING The following procedure uses dry- cleaning solvent, whichis flammable and must not be used near heat, ase or open flame, Inhalation of its vapors or prolonged contact with the liquid can cause gerious injury. NOTE The method fer applying lubricant in the following procedure Is outlined in R-3896-3, 3-92 Change No. 9 - 2 December 1970 b. Clean threads of hypergol manifold car- tridge container inlet port with drycleaning solvent (Federal Specification P-D-680). Lu- bricate (Method A) threads with lubricant grease RBO140-012 (Rocketdyne), CAUTION When installing the hypergol system test tool into the hypergol manifold cartridge container inlet port, ex- treme care must be used to prevent damage to the hypergol cartridge follower. # The threads of the test tool cap musi be clean and fre. of nicks to prevent galling the threads of the cap and in- let port. c. Make sure that threads of test tool cap are clean and free of uicks, lubricate (Method L) cap packing with £81281 grease (Dow Corning Corp); then carefully insert hypergol system test tool 9021278 into hypergol cartridge container inlet port, and serew cap (clockwise) onto inlet port until if bottoms. NOTE During oxidizer dome flushing, the engine must be maintained in null position with stage and engine in vertical position. e If heat exchanger check valve is pressurized at 4-psig minimum, proceed to step e. d. Remove heat exchanger check valve, and install a suitable test plate on thrust chamber oxidizer doine outlet port. e. Verify that any test instrumentation lines that could trap trichloroethylene during flush are disconnected and ports capped off f. Install Oxidizer Dome Flushing Kit G2030 (paragraph 3. 5.1.1). . Remove pressure cap from, and connect thrust chamber fuel jacket purge system to, fuel jacket purge quick-discunnect on each fuel valve. If thermal insulation is installed, gain access to fuel jacket purge quick- disconnect on No. 1 fuel valve by loosening insulator 145510 ae outlined in paragraph 3. 5. 16. R-3806-11 h. Remove pressure cap from, and connect kypergol servicing purge system to, hypergol purge quick-discennect. i, Remove pressure cap from, and connect an oxidizer-clean source of gaseous nitrogen (MIL-P-27401) capable of supplying 175 +25 psig under flow conditions to, flushing kit manifold GN, inlet port. j. Remove pressure cap fram, and connect LOX dome and gas generator LOX injector flushing system tc, flushing kit manifold tri- chloroethylene inlet nipple. k. Remove thrust chamber throat security closure (paragraph 3. 6. 14). l, Remove plug from gas generator combus- tor drain port and connect a Suitable drain hose to port. m. Pressurize flushing kit pneurnatic system lo 175 +25 psi as indicated on flushing kit GNy gage. n. Pressurize hypergol servicing purge sys- tem to 150 +50 psig. o. Pressurize thrust chamber fuel jacket purge system to 300 4100 psig. WARNING The following procedure uses tri- chloroethylene, which is a toxic solvent. Inhalation of its vapors or prolonged contact with the liquid can cause injury or death. ma LUBRICATE DORE UY LUARICATE ( : PACKINGS ‘e } AREA TO BF a = iUBRICATED Fi 11-10A Figure 3-9. Lubricating Hypergol Manifold Bore Section If p. FPressurize LOX dome and gas generator LOX injector trichloroethylene flushing system to 90 +10 psi as indicated on flushing kit trichlo- roethylene gage, flush thrust chamber oxidizer dome and gas generator oxidizer injector cavity for a minimum of 30 seconds, and verify flow through drain hose installed in step 1. Depres- surize flushing kit trichloroethylene system, and wait 2 minutes before proceeding to next step. q. Depressurize thrust chamber fuel jacket purge system, r. Depressurize hypergol servicing purge system. s. Depressurize flushing kit pneumatic system. t. Disconnect LOX dome and gas generator LOX injector flushing system from flushing kit manifold trichloroethylene inlet quick- disconnect, and reinstall pressure cap. u. Pressurize flushing kit pneumacic system to 175 425 psig. v. Pressurize hypergol servicing purge sys- tem to 150 +50 psig. w. Pressurize thrust chamber fuel jacket purge system to 300 4100 psig. x. Allow purges to flow for 5 minutes mini-~- mum, continue until all vapors are expelled from thrust chamber before proceeding to next step. y. Depressurize thrust chamber fuel jacket purge system. a. Depressurize hypergol servicing purge system. aa. Depressurize flushing kit pneumatic system. ab. Disconnect 4 hoses fram thrust chamber oxidizer dome; then remove reducers and adupter manifolds, if applicable, from bosses on thrust chamber oxidizer dome, and reinstall reducers on hoses. Install pressure caps on reducers to prevent entry of contaminants. Change No. 9 - 2 December 1970 3-93 Section IT ac. See figure 3-10, and temporarily dis- connect dome flushing kit bracket 9012790 from thermal insulation bracketry to gain access to oxidizer side of gas generator. Support bracket while disconnected. ad. Remove 3 bolts thal secure flushing kit adapter io gas generator ball valve. Remove adapter from ball vaive. Install cover on adapter to prevent entry of contaminants. ae. Install gas generator purge check valve as follows: (1) Remove test plate and protective closure, and install gas generator purge check valve, oxi- dizer purge tube, and seal 120D26)-3010-0009 on gas venerator ball valve with 3 bolts and washers. Torque bolts tu 40-50 in-lb, Safety- wire bolts with Inconel lockwire MS20995N, (2) Insert seal 19-406332-5 between gas generator oxidizer purge tube and purge mani- fold, and verify that sev) 19-406332-5 is be- tween manifold and purge tube; then connect purge tube to manifold with 4 bolts and washers. Torque bolts to 70-80 in-lb. Safetywire bolts with Inconel lockwire MS20995N. af. See figure 3-10, and reconnect deme flushing kit bracket 9012790 to thermal insula- tian bracketry. f FITTING “UT ee Ste OXIDIAE R DOME - 10 FRAME XIDVe : |: G pant aelae FLUSHING KIT ae irae MANTEOLD baa sy bie ee ee i MATS STRUT oe 2 eh ee ae . mitt) , ieee, Peace 5 ' a ah fr OM TER “ ST RUE mee INGE TE STREET THUATF FLUSHING KIT BRACKET 9012790 BI-LT VA Figure 3-10. Oxidizer Dome Flushing Kit Manifold Bracket InstaJlation 3-94 Change No. 12 = 23 August 1971 R- 3896-11 ag. Remove any plugs installed in step e. ah. Turn on operational high-level LOX dome and gas generator LOX injector purge system. ai. Pressurize flushing kit pneumatic system to 175 +25 psig. aj. Pressurize hypergol servicing purge system to 150 150 psig. ak. Pressurize thrust chamber fuel jacket purge system to 300 +100 psig. CAUTION Leak-test compound must nol be used on flex line bellows since it cannot be remuved from the bellows. al, Using leak-test compound (MIL- L,- 25567), leak-test gas gencrator oxidizer purge manifold joints and gas generator purge check valve tu gas generator call valve joint. No leakage is allowable. am. Allow purges to flow for 5 minutes min- imum, continue until all vapors are expelled from thrust chamber exit and gas generator drain port before proceeding to next step. an. Depressu ‘ize hypergol servicing purge system. ao. Depressurize thrust chamber fuel jacket purge system. ap. Depressurize flushing kit pneumatic systein, aq. Turn off operational high-level LOX dome and gas generalor LOX injector purge system. ar. Hf heat exchanger check valve was re- moved in step d, remove thrust chamber oxi- dizer dome outlet port cover and reinstall heat exchanger check valve as outlined in R-3896-3. ag. Disconnect pneumatic system from hy- pergo] purge quick-disconnect. Remove pack- aging and install pressure cap. Torque pressure cap to 30-40 ft-lb. Safetywire pressure cap with Inconel lockwire MS20995N. at. Disconnect pneumatic system from each fuel jackel purge quick-disconnect. Remove packaging and install pressure caps. Torque pressure caps to 36-40 ft-lb. Satctywire pres- sure cap with Inconel lock’ ire MS20995N., atA. If thermal insulation is installed, secure insulator 145510 as outlined in paragraph 3.5.16. R- 3896-11 NOTE The method for applying lubricant in the fcllowing procedure is outlined in R-389€-3, au. Remove combustor drain hose. Remove plugg and seais from packaging. Lubricate (Method A) threads of plug with lubricant grease RBO140--012 (Rocketdyne), and install plug RId273-6003-0004 and K-seal 12100AA4 in com- bustor drain boss. Torque plug to 200-240 in- lb. Safetywire plug with Inconel lockwire MS20995N. av. Romove plugs and seals from packaging. Lubricate (Method A) plugs with lubricant grease RBO140-012 (Rocketdyne) and (Method R) new K-seals with lubricant grease RBO140-012 (Rocketdyne) or fluorinated oi] Krytox 143AZ, (Du Pont), and install 6 plugs and K-seals in thrust chamber oxidizer dome purge porcs, Install plugs AN814-8.11. and K-seals 12109CR8 in bosses PURGE 1A, PURGE 1B, PURGE 24, and PURGE 2B. Torque plugs to 350 415 in-lb, Install plugs ANB14-12CL andK-scals 12100CR12 in bosses NO, 3 PURGE and NO. 4 PURGE. Torque plugs to 80 310 ft-Jb. Safetywire plugs ‘ith Inconel lockwire MS20995N. aw, Remove oxidizer dome flushing kit G2030 (paragraph 3.5.1.2). ax. Remove hypergol system test tool. WARNING The fnHowing procedure uses dry- cleanipg solvent, which is slammable and must not be used near heat, sparks, or open fiame. Inhalation of its vapors or prolonged contact with tne liquid can cause serious injury. ay. Clean threads of hypergol] cartridge container inlet port with drycleaning solvent (Federal Specification P-1D- 680), az. Remove hypergol cartridge container in- let port closure from packaging. Lubricate (Method L) closure packing with F$1281 grease (Dow Corning Corp) and install closure. Secure closure with attaching pin. ba, Remove plugs and install any Instrurnen- tation lines removed in step e. WARNING The {ollowing procedure uses clean- ing compound, whichis volatile. Use ina well-ventilated area since the vapors displace the oxygen in the air, resulting in suffocation. Section IIL Paragraph 3.5.1.1 bb. Remove all leak-test compound from all joints and fittings with a clean, dry cloth or by flushing inaccessible areas with cleaning com- pound (MIL-C-81302), 3.5.1.1 Oxidizer Dome Flushing Kit Installa- tior for ome and Gas Generator LOA Injector Flush. The following procedure may be Used on engines with or withoul thermal insula- tion panels installed but with thermal insu.alion brackeiry installed. See figure 2-5, and install oxidizer dome flushing kit as folluws: a. If thermal insulation panels are installed on engine, see figure 2-15 and remove the fol- lowing thermal insulation panels: (i) Thrust OK pressure switches and ox1- dizer dome purge and flush ports (2) No. 1 oxidizer dome flush and purge ports {3) No. 2 oxidizer dome flush and purge ports {4} Gas generator oxidizer purge check valve (5) Gas generator igniters a4. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3.1A when perforraing this test. b. Verify that nut on fitting installed in oxi- dizer dome flushing kit No. 5 0809 port is safety wired to frame and that aluminum seal is installed. If lockwire of aluminum seal is missing, verify that oxidizer dome flushing kit is correctly assembied and leak tested as out- lined in R-3896-5, prior to proceeding with test. c. On uninstalled engines, install flushing kit j manifnld adapter 9022108 as follows: (1) Renove 4 bolts, 4 washers, and seal plate that secures gas generator oxidizer purge tube to purge manifold. (2) Remove 3 bolis, 3 washers, and seal that secures gas generator purge check valve to gas generator ball valve; then remove check valve together with gas generator oxidizer purge tube. (3) Install protective closures on purge tube and check valve. (4) Install flushing kit manifold adapter 9022108 in gas generator oxidizer purge port, Torque the 3 mounting bolts to 40-50 in-lb, Chang2 No, 12 ~ 23 August 1973 3-95 Section Uf (5) Connect hose R3806-12-0800 to adapter 9022108. See figure 2-5 for hese routing when thermal insulation is installed. Toi que hose coupling nuts to 900-1,100 in-lb, Protect loose snd of hose from contamination, NOTE Step cA is required only far first flushing operation on installed engines, cA, On installed engines, to prevent frosting of gas generator purge check valve during flushing, perform the following. (1) On all engines, remove gas generator purge check valve and gas generator oxidizer purge tube as follows: (a) Remove 4 bolts, 4 washers, and seal plate that secures gas generator ox’ ‘izer purge tube to purge manifold, (b) Remove 3 bolts, 3 washers, and seal that secures gas generator purge check valve to gas generator ball valve: then remove check valve together with gas generator oxidizer purge tube, {2} Op all engines, install test plate T-5047892 on purge manifold using bolts, washers, and seal plate removed in substep 1, a. Install bolts fingertight; (hen on engines not being Slusned, toxque bolts to 70-80 in-Ib, (3) On engines not being flushed, austall closures on gas generator oxidizer purge port, (4) On engines being Nushed, install flushing kit manifold adapter 9022108 as follows: (a) Install flushing kit manifold adapter 9022108 in gas generator oxidizer purge port. Torque the 3 mounting bolts to 40-50 in-lb, (b) Connect hose R3806-12-0800 to adapter 9022108, See figure 2-5 for hose routing when thermal insulation is tstalled, Torque hose coupling muts to 900-1,000 in-1b. Protect loose end of hose from contamination, NOTE Slep cB is required only after first flushing operation on installed engines, 3-96 Change No, 12 - 23 August 1971 It-3896-11 cB, On engine to be flushed, remove ciosure from gas generator oxidizer purge port and install flushing kit manifold adapter 9022108 «us follows: (1) Install flushing kit manifold adapter 9022108 in gas generator oxidizer purge port, Torque the 3 mounting bolts to 40-50 in-Jb, (2) Connect hose R3806-12-0800 to adapter 9922108. See figure 2-5 for hose routing when thermal insulation is installec Torque huse coupling nuts to 900-1,000 in-Jb. Protect loose end of hose from contamination, d. See figure 3-10, and position dome flushing kit bracket 9012790 in thermal insulation brack- etry holes, When thermal insulation is installed, position main strut o’ bracket as far from gas generator as thermaid insulation access door will perinit, Secure bracket in place by securing inner strut to outer strut with attached pin, e, Position oxidizer dome flushing kit mani- fold on dome flushing kit bracket and secure with attached pin, f, See figure 2-5, and connect hoses between oxidizer doe flushing kit manifold and engine as icllows: (1) Remove plugs from thrust chamber oxi- dizer dome bosses PURGE 1A and PURGE IB, NOTE In the following procedure, in steps requiring hose coupling torque in excess of torque required for unions or reduc. rh, unions or reducers must be held to avoid overtorquing, ® The method fer applying lubricant in the following prourr.ure ts outlined in R-3996-3, (2) Lubricate (Method A) reducer with lubricant prease RBO140-012 (Pocketdyne) and (Method R) K-seal with lubricant grease RBO140-012 (Rocketdy¢) or fluurinated oil Kr tox 149A4Z (Du Pont), anc install reducer ANS$19-15C, K- ‘eal 12100CRR, aud adapler 9024153 from adipter kit 9024165 in thrust chamber oxidizer dome bosses PURGE 1A and PURGE 1B, Torque reducer to purge boss connections to 300-720 in-lb, Torque house coupling nuts to reducer to 650-750 in-Ib, R-3896-11 (3) Install hose R3806-12-0500 between adapter manifold in bosses PURGE 1A and PURGE 1B and flushing kit manifold port No, 1 0500, Torque hose coupling nuts 900-1, 100 in-lb, (4) Remove plugs from thrust chamber oxi- dizer dome hesses PURGE 2A and PURGE 2B, (5) Lubricate (Method A) reducer with lubricant grease 1B0140-012 Gtocketdyne) and (Method R) K-seal with lubricant grease RRO140-012 (Rocketdyne) or fluorinated oil Krvtox 14844 (Du Pout), and ‘astall reducer AN919-15C. K-seal 12400CR8, and adapler 9024153 in thrust chamber oxidizer dome busses PURGE 2A and PURGE 2B. Vorque reducer to purge huss connection to 300-720 in-lb. Torque coupling nuts at reducer to 650-750 in-lb, (6) Install hose 23806-12-1006 between adapter mauiiola in bosses PUIGE 2A and PURGE 2B and flushing kit manifold port No. 21000. ‘Torque hose coupling nuts to 900- 1,100 in-tb. (7) Remove plug froin thrust chamber oxi- dizer dome hoss NO. % PURGE, (8} Lubricate (Methud A) reducer with lubricant grease RBO140-012 (Rocketdyne) and (Method R) K-seal with lubricant grease RBO140-012 (Rocketdyne) or fluorinated oil Krytox 143AZ (Du Pont), and install union AN815-12C and K-seal 12100CR12 in thrust chamber dome boss NO, 3 PURGE. Torque unius tu 420-500 ia-Jdb, (2) install hose 1t4896- 12-0600 between nnion in thrust chamber oxidizer dome boss NO. 2?) o VGH and flushing kit manifold port No. 3 0600. Torque hose coupling nuts tu 960- 1,100 in-Ib, (10) stemove plue from thrust chamber oxi- dizer dome boss NO, 4 PURGE. (11) Lubricate (Method A) reducer with lubricant grease 1BO140-012 (Rockeidyne) and (Metnod R) K-seal with lubricant grease RBO140-9/2 (Rocketdyne) or fluarinated oil Krytox 14342 (Du Pont), and install union ANU32-127 and K-seal 12100CRI2 in thrust chamber oxidizer dome boss NO. 4 PURGE, Torque wiion to 420-600 in-Ib, Change No, 12 - 23 Augusi 1971 Section Il (12) Instell hose R3806-12- 1080 between union in thrust chamher oxidizer dome boss NO. 4 PURGS# and flushing kit manifold port No, 41080. Torque hose coupling nuts to 900- 1,100 in-)b. (13) Install hose R3806- 12-0800 between adapter 9022108 and flushing kit manifold port No, 50800. Torque hose coupling nuts to 900- 1,100 in-Ib, 3-954 °3-961 H-3896- 11 (14) Remove plugs from taps GF2a and GE2h., NOTE The method for applying lubcicant in the following procedure is outlined in R-3806-3. (15) Install flushing kil manifold diffusers 9023934 with K-seals 12100AA4 in taps GF2a and GF2b. Lubricate (Method A) diffuser with lubricant grease KBO140-012 (Rocketdyne), Torque diffusers to 260-240 in-Ib. (16) Connect hoses 19-9014938-11 at flush- ing kit manifold 9025254 to diffusers. Torque hose coupling nut to 270-345 in-lb, 3.5.1.2 Ojvidizer Dome Flushing Kit Removal, for LOX Dome and Gas Generator LOX Injector Flush. a. Disconnect hoses frow Alushing kit mani- fold 9025254, Install pressure caps on manituld fittings and plugs in end of hoses, bh, Remove flushing kit manifold 9025254 from dome flushing kit bracket 9012790: then disvonnect dome flushing kit brackel from thermal insulation bracketry. NOTE The method for applying lubricant m the following procedure is outlined in R-3896- 3. Remove diffusers from taps GF2a and GFab. Remove plugs and K-seals from packag- ing. Lubricate (Method A) plug threads with lubricant grease RBU140-012 (Rocketdyne), and install plugs RD273-~- 6003-0004 and K-seals 12100AA4 in instrumentation taps GF2a and GF2b. Torque plugs ta 200-240 in-ib. Safety- wire plugs with Inconel lockwire MS20995N. 3.5.2 LOX DOME * LUSH. This procedure contains instructions for flushing the thrust chamber oxidizer dome, NOTE When performing this procedure with the engine environmental cover in- stalled, the rope that secures the exit end of the cover must be untied and the end of the cover turned up and secured to prevent trichloro~- ethylene from accumulating in the cover. At the completion of the procedure, the cover must be low- ered and secured in accordance with paragraph 3, 6. 5. Scction IIT Paragraphs 3.5.1.2 to 3.5.2 ein steps requiring hose coupliuig torque in excess of torque required for fittings, fittings must be held to avoid overtorquing. a. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3. 1A when performing this test. aA. Remove pin and closure from hypergol manifold cartridge container inlet port. WARNING The following pracedure uses dry- cleaning solvent, whichis flammable and must not be used near heat, spatks, or open flame, {nhalation ef its vapors or prolonged contact with the liquid can cause serious injury. NOTE Tie anethod for * pplying lubricant in the following procedure is outlined in R-3896- 3 b, Clean threads of hypergol manifold car- tridge container inlet port with drycleaning sulvent (Federal Specification P-)-680). Lu- Vricate (Method A}threads with lubricant grease RBO140-012 (Rocketdyne). See figure 3-9, and lubricate bore of containey with F$1281 grease (Dow Corning Cary). CAUTION When installing the hypergol system test toul into the hypergol manifold cariridge container inlet port, ex- treme care rust be used to prevent damage to the hypergol cartridge follower. e The threads of the test tool cap must be clean and free uf nicks to prevent galling the threvds of the cap and inlet port. c. Make sure that threads of test tool cap are clean and free of nicks, lubricate (Method L) cap packing with F51281 grease (Dow Corning Corp); then carefully insert hypergol systera test tool 9021279 into hypergol cartridge con- tainer inlet port, and werow cap (clockwise) anto inlet port until it boltums. Change No. 9 - 2 Decembrr 1970 3-97 Section II NOTE During oxidizer dame flushing the engine must be maintained in a null position with stage and engine i1 « vertical positton, @ If leat exchanger check valve is pres- surized at 4-psig gaseous nitrogen pressure, proceed ta step e. d. Remove heat exchanger check valve, and install a suitable tes! plate on thrust chamber oxidizer dome outlet port. e. Verify that any test instrumentation lines that could trap trichlorgethylene during flush are disconnected and ports capped off. f. Install Oxidizer Dome Flushing Kit G2030 (paragraph 3. 5. 2. i). g. Remove pressure cap fram, end connect thrust chamber fuel jacket purge system to, fuel Pipes purge quick-dseunnect on e2ch fuel valve, f thermal insulation is installed, gain access to fuel jacket purge yuick-diseonnect on No. 1 fuet valve by loosenin insulator 145510 us out- lined in paragraph 3. 5. 16, h. Remove pressure cap from, and connect hypergol servicing purge syatem to, hypergot purge quick-disconnect, i. Remove pressure cap from, and connect an oxidizer-clean source of gaseous imtragen (MIL- P-27401) capable of aupplyong 175 +25 psig under flow condiuons to, flushing kit manifold GN, inlet port, j. Remove vressure cap trom, and connect LOX dome and gas generator LOX injector flushing system to, flashing kit manifold tri- chinroethylene inlet nipple. k. Reroove thrust chamber throat security § closure (paragraph 3.6. 14). 1. Pressurize flushing kit pneumatic system to 17% +25 psi as indicated on flushing kit GN gage. 7 m,. Pressvrize hypergol servicing pwirge system to 150 +60 psig. n. Pressurize thrust chamnher fuel jacket purge system to 300 4100 psig. 3-94 Change No. 9 = 2 December 1970 R-3896- 11 WARNING The {ullowing procedure uses trichlo- roethylene, whic. is a toxic solvent. Inhalation of its vapors or prolonged contact with the liquid cun cause injury or death. o. Pressurize LOX dome and gas generator LOX injector trichloroethylene flushing system to 00 +10 psi as indicated on flushing kit trichlo- rocthylene gage, and flush thrust chamber oxi- dizer dome for a minimum of 30 seconds. De- pressurize tlushing kit trichloroethylene system, and wait 2 minutes before proceeding to next Step, p. Depressurize thrust chamber fuel jacket purge systen. q. Depressurize hypergol servicing purge system. r, Depressurize flushing kit pneumatic system. Ss. Disconnect LOX dome and gas generator LOX injector flushing system from flushing iit mantfold tuichloroethylene inlet quick- disconnect}, and reinstall pressure cap. t. Prossurize flustung kit pneumatic system to 179 425 psig. u. Pressurize hypergol servicing purge sys- tein to 150 450 psig. vy. Pressurize thrust chamber fuel jacket purge system fo 200 1100 psig. w. Allow purges to flow for 5 minutes mini- mum; continue until al) vapors are expelled front thrust chamber before proceeding to next step. x. Depressurize thrust chamber fel jacket purge system. y. Depressurize hypergol servicing purge system. 2. Depressurize flushing kit pneumatic system. R- 3896-11 aa. Disconnect 4 hoses from thrust chamber oxidizer dome; then remove reducers and adapter manifolds, if applicable, from bosses on thrust chamber oxidizer dome, and reinstall reducers on hoses, Install pressure caps on reducers to prevent entry of contaminants, ab. Remove any plugs installed in step e. ac. Turn on operational high-level LOX dome and gus generator LOX injector purge system, ad. Vressurize hypergol servicing purge pystem to 150 :50 psig. ae. Pressurize thrust chamber fucl jacket purge System to dQQ «100 psig. af, Allow pnutges ta flow for S$ minutes mimt- Mun, continue unti] all vapors are expelled from thrust chamber exit. af. Depressurize hypereol servicme puree system, ah, Depress sarize thrust chamber fuel jacket purge syste... ut. (Deleted) aj. Turn off operational high-level LOX dome and gas generator LOX injector purge system. ak, ff heat exchanger check valve was re- moved in step d, remove thrust chamber oxi- dizer dome cutlet port cuver and reinstall heat exchanger check valve as outlined in R- 3890-38, al, Disconnect pneumatic system from hy- pergol purge quick-disconnect, Remove pres- sure cap from packaging, and instal] pressure cap, Torque pressure cap to 30-40 ft-lb. Safetywire pressure cap with Inconel lockwire MS20996N, am. Disconnect pneumatic system from cach furl jacket di ay e quick-rlisconnect. Remove pressure caps from packaging. and install pres- sure caps. Tenaie pressure caps to 30-40 ft-th, Safetywire pressure caus with Inconel lockwire MS20995N amA,. Hf thertoal insulation is instalied, secure insulator 140010 as outlined in para- graph 3,0, 16. NOTE The method for applying lubrieant in the following procedure is outlined in R-3896-3, an. Remove piugs and K-seals from packag- ing, Lubricate (Method A) plugs with lubricant grease RBO40-012 (Ruockeldyne) and (Method R) new K-seals with lubricant gresse RBO140-012 Section Hi Javagraph 3.5.2, 1 (Rocketdyne) ov fMuarinated ofl Krytos 143A4 i (Da Bont), and install 6 plugs and K-seals in thrust chamber oxidizer dome purge ports, In- stall plugs AN&14-8C], and K-seals i2100CR8 in bosses PURGE TA, PURGE 1B. PURGE 2A, and PURGE 28. Torque plugs to 350 115 in-th, i Install plugs AN8BL4- a and K-seals 12100CRI12 tin hosses NO, 3 PURGE and NO, 4 PURGE. Torque ee to 80 +10 ft-lb, Safety- 9 wire plugs with Inconel lockwire MS2Z0995N, au, Remove oxidizer dome flushing kit G2030 (parapraph 3.5.2.2). ap. Remove hypergol system test tool, WARNING The following procedure uses dry- cleaning solvent, which is tlammable und must not be used near heat, sparks, or openflame, Tnhalation of its vapors or protonged contact with the Jiauid can cuise Serious injury. aq. Clean tareads of hypergol cartridyre container indet port with drycleaning salvent (Vederal Specification P-D- 680), ar. Remove hyperzol cartridpe container in- let port closure. Lubricate (Method I.) closure packing with P5128) grease (Dow Corning Corp) and tnstall closure, Secure closure with attaching pin, as. Reimove plugs and install any instru- mentation hne renioved in step ec. 3,5.%.4 Oxidizer Done Flushing Kit Installa- tion for LOX Dome Flush. The fallowing pro- cedure: may be used on engines with or without thermal insulation pancl installed but with brackelry inslaned, See figure 2-5, and instal oxidizer dome flushing kit as follows: a. If thermal insulation panels are installed on engine, see figure 2-15 and remove the fol- lowing thermal insulation panels. (J) Thrust OK pressure switches and oxi- dizer dome purge anc flush ports (2) No. 1 oxidizer dome flush and purge ports (3) No, 2 oxidizer dome flush and purge poris (4) Gas generator oxidizer purge check valve aA. Perform, as applicable, contamination and damage prevention procedures outlined in paragragh J. 1A when performing this test. Change No. 6 - 9 September 1970 3-99 section TL ). Verify that nut on fitting installed in oxi- dizer dome flushing kit No. 5 0800 port is saletywired to frame and that aluminum seal is installed. If lockwire of aluminum seal is missing, verify that oxidizer dome flushing kit is correctly assembled and leak tested as out- lined in R-3896-5, prior to proceeding with test, c. See figure 3-10, and position dome flush- ing kit bracket 9012790 in thermal insulation bracketry holes. Secure bracket in place by securing inner strut to outer strut with attached pin, dt. Position oxidizer dome flushing kit mani- fold on dome flushing kit hracket and secure with attached pin. e. See figure 2-5, and connect nose between oxidizer dome flushing kit manifold and engine 2s follows: (1) Remove plugs from thrust chamber oxidizer dome bosses PURGE tAand PURGE Ib. NOTE Tn the folloving procedure, in steps requiring hose coupling torque in ex- cess of torque required for unions or reducers, unions or reducers rust be held to avoid overtorquing. ® The method for applying lubricant in the following procedure is outlined in R-3896-3, (2) lubricate (Method A) veducer with lubricant grease RBO140-012 (Recketdyne) and (Method R) K-seaj with lubricant grease RBO140- 012 (Rocketdyne) or fluorinated oil Krytox 143A% (Du Pont), and install reducer - N919-15C, K-seal 12100CRA, and adapter 9u24953 from adapter kit 9024165 in thrust chamber oxidizer dome bosses PURGE JA and PURGE 1B. Torque reducer to purge boss connections to 300-720 in-lb, Torque hose coupling nuts tu reducer to 650-750 in-Ib. (3} Install hose K3806- 12-0500 between adaptor manifoid in bosses PURGE 1A and PURGE 1B and flushing kit manifold port No. 10500. Torque hose coupling nuts to 9a0- 1,100 in-th, (4) Remuve plugs from thrust chamber dome bosses PURGE 2A and PURGE 2B, J-100 Change No. 8 + 9 September 1970 R- guh6-14 (5) Lubricate (Method A) reducer with lubricant grease RBO140-012 (Rocketdyne) and {Method R) K-sea) with lubricant grease RBO140-012 (Rocketdyne) or fluorinated oil Krytox 143424 (Du Pont), and install reducer AN919-15C, K-seal 12100CR8, and adapter 9024153 in thrust chamber oxidizer dome bosses PURGE 2A and PURGE 2B. Torque reducer to purge boss connection tu 300-720 in-lb. Torque coupling nuls al reducer to 650-750 in-Ib, (6) Install hose R3806- 12-1000 between adapter manifold in bosses PURGE 24 and PURGE 28 and flushing kit manifold port No. 2 1000. Torque hose coupling nuis to 900- 1,100 in-Vb. (7) Remove plup from thrust chamber dome boss NO, 3 PURGE, (8) Lubricate (Method A) reduce with lubricant grease 2B0140-012 (Rocketdyne) and (Method R) K-seal with lubricant grease RBO140-012 (Rocketdyne) or fluorinated oil Krytox 148AZ (Du Pont), and install union AN815-12C and K- seal 12100CR12 in thrust chamber dome boss NO. 3 PURGE. Torque union to 420-600 in-Ib. (9) Install hose R3806- 12-0600 between union in oxidizer dome hoss NO, 3 PURGE and flushing kit manifoid port Ne. 3 0600. Yorgue hose coupling nuts to 900-1, 100 in-Th, (10) Remove plug from thrust chaniber dome buss NO. 4 PURGI, (11) Lubricate (Methed A) reducer with lubricant grease RBQ140-012 (Nucketdyne) and (Method R) K-seal with lubricant grease RF0140-012 (Rocketdyne) or Ouorinated vil Krytox 143AZ (Du Pont), and install union ANG32-127 and K-seal {2160CR12 in thrust chamber dome boss NO, 4 PURGE. Torque union to 420-600 in-lh. (12) Install hose R3GOG- 12-1080 between union io thrust chamber dume boss NO, 4 PURGE gnd Oushing kit manifold port Ne. 41080. Torque hose coupling nuts to 300- {,100 in-Jb, R-3806-31 f. See figure 2-15, and connect hoses be- tween oxidizer dome flushing kit manifold and a Suitable facility drain as follows: NOTE In the following procedure, in steps requiring hese coupling torque in ex- cess of lorque required for unions or reducers, unions or reducers must he held ta avaid avertorgning (1) Install hose R3806- 12-0800 between adapter 9622108 and flushing kit manifold port No. 5.0800. Torque hose coupling nuts to $00- 1,100 in-tb. (2) Connect hoses 19-9014938-11 at flush- ing kit mmanifold 9025254 to diffusers. Torque hose coupling nul to 270-345 in- tb. (3) Position outlets of adapter 9022108 and diflusers 9029934 into a suitable facility drain and secure hoses ta prevent whinping when flowing gaseous nitrogen or trichloro- ethylene. (4) Notify personnel, as applicable, to keep clear of hose exits during flushing opera- tion. 3.5.2.2 Oxidizer Dome ie Flushing Ki Kit Removal for LOX Dome Flush. a. Disconnect hoses from flushing kit mani- fold 9025254 and install caps on manifold fittings. Install pressure caps on manifold fittings and plugs in end of hoses. b. Remove flushing kit manifold 9025264 from dome flushing kit bracket 9012790; then disconnect dome flushing kit bracket from thermal insulation bracketry. ec. Disconnect diffusers from adapter 9024153 and install caps on open lines, as applicable. 3.5.3 GAS GENERATOR LOX INJECTOR FLUSH. This procedure contains instructions for flushing the gas generator oxidizer injector. Section UI Paragraphs 3.5.2.2 to 3.5.3 NOTE When perforialug this procedure with the engine environmental cover in- stalled, the rope that secures the exit end of the cover must be untied and the end of the cover turned up and secured fo prevent trichloroethylene from accumulating in the cover. At the Baas of the procedure, the rover be lowered and securcd in eecaice with paragraph 3.6.5. Th steps requiring hose coupling torque in excess of torque required for fittings, fittings must be held ta avoid overtorquing. a. Perform, es applicable, contamination and damage prevention procedures outlined in paragraph 3,14 when performing this pro- cedure, aA. Install Oxidizer ome Flushing Kit G2630 (paragraph 3.5.3.1). b. Remove pressure cap from, and connect an oxidizer-clean source of gaseous nitrogen (MIL- P- 27401) capable of supplying 175 425 psig under flow conditions to, flushing kit mani- fold GN, inlet port. c. Remove pressure cap from, and connect LOX dome and gas generator LOX injector flushing system ta, flushing kit manifold tri- chloroethylene inlet nippic. d. Remove plug from gas generator combus- tor drain port and connect a suitabie drain hose to port. e. Remove thrust chamber throat security closures (paragraph 3. 6, 14). f. Pressurize flushing kit pneumatic system to 175 425 psi as indicated on flushing kit GN page. Change No. 9 - 2 December 1970 3-101 Section If WARNING The following procedure uses tri- chloroethylene, which is a toxic solyent. Inhalation of its yapors or prolonged contact with the liquid can cause injury or death. g. Pressurize LOX dome and gas generator LOX injector trichloroethylene flushing system to 90 +10 psi as indicated on flushing kit tri- chiurocuiylene gage, fiushgas peneratue usidi2es injector cavity for 30 seconds minimum, and verify flow through drain hose installed in step d; then depressurize flushing kit (richloro- ethylene system. h. Depressurize flushing kit pncumatic System, i. Disconnect LOX dome and gas generator LOX injector flushing system fram flushing kit mantfold triehtoroethylene inlet quick- disconnect, und reinstall pressure cap. i, Pressurive flushing kit pneumatic system (o 175 425 psig. k. Allow purges to flow for 5 minutes mini- mum; continue until all vapors are expelled from turbine exhaust manifold before proceed- ing to next step, Ll. Depressurize flushing kit pneumatic system, ia. See figure 3-10, and temporarily dis- connect dome flushing kit bracket 9012790 from thermal insulation bracketry lo gain access io oxidbser side of gus generator. Suppasrt brackel while disconnected. mn. Remove 3 bolts that secure flushing kit adaptor to gas generaior ball valve. Remove adapter from bal! valve. Tnstall cover on adapter to prevent entry of cuntaminants. 9 Install gas generator purge chock valve as follows. (1) Remove test plate and protective closure, and install gas generator purge check valve, oxidizer purge tube, and geal RN261-30)0-0009 on gas generator ball valve with 3 bolts and washers, Torque bolts to 40-50 in-ib, Safetywire bolts with Inconel lockwire MsZ0995N, 3-102 Change No. 12 - 23 August 1971 R-3896-11 (2) Insert seal ta-~406332-5 between gus generator oxidizer purge tube and purge mani- fold, and verify that seal 19- 406332-5 is octween manifold and purge tube; then connect purge tube to manifold with 4 bolts and waghers. ‘Torque bolts to 70-80 in-lb. Safetywire bolts with Inconel lockwire MS20995N. p. See figure 3-10, and reconnect dome flushing kit bracket 9012790 to thermal insula- tion bracketry. q. Turn on operational high-level LOX dome and gas generator LOX injector purge system. ry. Pressurize flushing kil pneumatic system to 175 +25 psig. CAUTION Leak-test compound must not be used on flex line bellows since 1t cannot be removed from the bellows. s. Using leak-test compound (MiL-~L-25567), leak-test gas generator oxidizer purge manifold joints and gas generator purge check valve ta gas generator ball valve foint. No ieakage is allowable. t. Alluw purges to flow for 5 niuinute. min.- mum; continue until all vapors are expelled from turbine exhaust manifold and gas generator drain port before proceeding to next step. uv. Depressurize flushing kit pneumatic system. v. Turn off operational high-level LOX dome and gas generator LOX injector purge system. NOTE The method for applying lubricant in the following procedure js outlined in R- 3896-3. w, Remove combustor drain hose. Remove plug and K-seal from packaging, labricate (Method A)plug threads with iubricant grease RBO140-012 (Rocketdyne), and install plug RD273- 6008-0004 and K-seal 12100AA4 in com-- bustor drain bosa. Torque plug to 200-240 in-lb. Safetywire plug with Inconel lockwire MS20995N, x. Remove oxidizer dome fi shing kit G2030 (pacagraph 3. 5,3. 2). ik 3806-1] Section Ii WARNING The following procedure uses clean- ingg compound, which is vonitile. Use ina well-ventilated area since the vapers displace the oxygen inthe air, resulting in suffocation. y. Remove all leak-test compound fromm all joints and fittings with a clean, Wy cloth, or by flushing inaccessible arcas with cleaning compound (MIL-C-#1302), 3.5.3.1 Oxidier r Done Flushuug Kit Installa- PCa eee en eet sas tion for Gas Generator LO LOX Injector Fhugk. Thy following procedure may he used on engines with or without thermal insulation panels in~ stalled but with bracketry installed, See figure 2-5, and install oxidizer dowe flushing Kit as follows: a. If thermal insulation panels are insta'led on engine, ec figure 2-15, and remove the Jollowing thermal insulation vanels: (1) Gas generator oxidizer purge check valve (2) Gas generator igniter: aA. Perform, ag applicable, contamination and damage prevention procedures outlined in paragraph 3. 1A whenperforming vbis procedure. b. Verify that nut on filting installed in oxi- dizer dome flushing kit No, 5 G80Q part is eae porn to frame and that aluminum seal is nstalled. If lockwire of aluminum ceal is cisuines verify that oxidizer dome flushing kit is correctly assembled and leak tested as out- lined in R- 3896-5, prior to proceeding with test. c. On uninstalled engines, install flushing kit manifold adapter 9022108 as follows: (1) Remove 4 bolis, 4 washers, and seat plate that secures gas generator oxidizer purge tube to purge manifold, (2) Remove 3 bolts, 3 washers, and seal thet secures gas generator puege check valve to gas generator ball valve; then rersove check valve together with gas generator oxidizer purge tube, (3) install protective closures on purge tube and check vaive. Paragraph 3. 5,3, 1 (4) Install flushing kit manifold adapter YG22108 in gas genorator oxidizer purge port. Torque the 3 niounting bolts to 40-50 in-Jb. (5) Connect hose R38e6- 12-0800 to adapter 9022108. See figure 2-5 fov hose routing when thermal insulation is installed. Torque hose coupling nuts to 900-1, 100 in-lb. Protect loose end of hose from contamination. NOTE Step cA is required only for first flushing operation on installed engines, cA, On installed engines, to prevent frosting of gas generator purge check valve during flush- ing, perfarm tie following. {1} On all engines, remove gas generator purge check valve and gas generator oxidizer purge tube as follows: (a} Remove -‘ bolts, 4 washers, and seal plate thal secures vas generator oxidizer purge tube to purge manifold, (b) Remove 3 bolts, 3 washers, and seal that secures gas generator purge check valve te gas venerator ball valve; then remove check valve togcther with gas generator oxidizer purge tube, (2) On all engines, Install test plate T~047892 on purge manifold using bolts, washers, and seal plate removed in substep 1, a. Install bolts fingertight; then on engines not being flushed, torque bolls to 70-80 in-ib, (3) Gn engines net being flushed, install closures on gas generator oxidizer purg.. port. (4) On engine being QNushed, install Nushing kit manifold adapter 9022108 as follaws: (a) ‘rstall flushing kit manifold adapter 9022108 in gas generator oxidizer purge pore, Torque the 4 mounting bolts te 40-50 in-lb, (b} Connect hose R38U6-12-0860 to adapte: 3922108, See figure 2-5 for hose routine, when thermal jigalation ls installed, Torague hose coupling ate to 900--1,000 in-lb. Protect loose end of huse fram centamination, Change Now 12 - 23 Aupust 19/1 3-103 Section III Paragraph 3.5.3.2 NOTE Step cB is required only after first flushing operation on installed engines, 4 6B. «6On engine to be flushed, remeve closure , from gas generator oxidizer purge port and 3 instoll flushing kit manifold adapter 9022108 Bas follows, : (1) Install flushing kit manifold adapter A 9022108 in gas generator oxidizer purge port. ) Torque the 3 mounting bolts to 40-50 in«lb, (2) Conneet hose RI8C6-12-0800 to adapter 89022108. See fieure 2-5 for hose routing when B therinal insulation is installed, Torque huse B coupMing nvis to 900-1,0G60 in-Ib, Protect y joose end of hose from contaniination. d. See fipure 3-10, and position dome flush- ing kit bracket 9021790 in thermal insulation bracketry hoies, When thermai insulation ig installed, posilion main strut of bracket as far from, gas generator as thermal insulation access door will permit. Secure bracket in place by securing inner strut to outer strut with attached pin, e. Position oxidizer dome flushing kit mani- fold on dome flushing kit bracket and secure with attached pin, f, See ficure 2-5, and connect hoses’ ctween oxidizer dome flushing kit and gas generator as follows: NOTE The following procedure, in steps requiring hose coupling torque in excess of torque required for unions or reducers, untons or reducers must be held to avoid overtorquing. {1} Install hose 13806 -12-0800 between adapter 9022108 and flushing kit manifold port No, 5 0200. Torque hose coupling nuts ta 200- 1,106 in-Ib, (a) Kkemove plugs from taps GFia aad GF2h, 3-104 Change No. 12 - 23 August 1971 R~- 3896-11 NOTE The method for applying tubricant in the following procedure is outlined in R-3896-3, (3) Install flushing kit maniiold diffusers 9023934 wilh K-seal t2L00AA4 in taps GF 2a and GFab. Lubricate (Method A) diffuser with lubricant grease RB0140-012 (Rocketdyne), Torque diffusers to 200-240 in--lb. (4) Connect hoses 19-9014938-11 at flushing kil manifold 9025254 to diffusers, Torque hose coupling nut to 270-345 in-ih, NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, g. Connect hoses including all their attach- ments (sec figure 2-5) between flushuag kit manifold and a suilable facility drain, Lubri- cute (Methad A) fittings, as applicable, with lubricant preuse BB9140-612 (Rocketdyne}, Torque hose voupling nuts to 900-1,100 in-Jb, h, Notify personnel, as applicable, to keep clear of hose exits during Uushing operation. 3.5.3.2 Oxidizer Dome Flushing Kit Removal fos Gas Generator LOX Injector Flash, a. Perform, as applicable, contamination and damnge prevention procedures outlined in paragraph 3,14 when performing this procedure, aA, Disconnect hoses from flushing kit mani- fold 9025254 and tnstall caps on manifold fittings. Install pressure caps on nianifold fittings and plugs in end of hoses, b. Remove Dushing Lit manttold 9025254 from dome flushing kit bracket 9012790; tLen disconnect dome flushing kit bracket from thermal insulavion bracketry. R- 3896-11 NOTE The method for applying lubricant in the following procedure is outlined in, R-3896-3, ce, Kemove diffusers from taps GF@a and GFeYb, Remove plugs and K-seals from packag- ing. Lubricate (Method A) plug threads with lubricant grease RBO140-012 (Rocketdyne), and install plugs RD273-6003-0004 and K-seals 12100AA4 in instrumentation taps GF2a and GF2b, Torque plugs to 200-240 in-th, Safety- wire plugs with Inconel lockwire MS20095N, 3.5.4 ‘THRUST CHAMBER FUEL JACKET ELUSH, This procedure contains instructions for removing residual fuel from the thrust chamber fuel intet manifold, thrust chamber fuel jacket, fuel valves, and fuel injection cavities, and provides a liquid leak test of the thrust chamber fuel jacket, The engine must be maintained in the vertical position with hydraulic pressure applied to the gimbal actuators or the ginibal actuator Jocks in- stalled during this procedure, NOTE When performing this procedure with the engine enviroumentel cover installed, the rope that secures the exit end of the cover must be untied aad the end of the cover turned up and secured to prevent trichloroathylene from accumulating in the cover, At the completion of the procedure, the cover must be lowered and secured in accordance with paragraph 3,6, 5, a. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3,14 when performing this procedure. NOTE If stage pre- valves are te be open and the fuel tank pressurized during this proredure, step aA must be omitted. aA. Remove pressure cap from, and attach a drain hoge to, drain quick-disconnect on No, L and Nu. 2 fuel high-pressure ducts, Change No. 12 ~ 23 August 1971 Section J Paragraph 3.5.4 b. Connect thrust chamber fuel jacket purge system to fuel jacket purge quick-disconnect on each fuel valve, If thermal insulation is installed, gain access to fuel jacket purge quick-disconnect on No. I fuel valve by loosen- ing inswator 145510 as outlined tn paragraph 3.9,16, c. Check that thrust chamber exit manifold drain plugs are in closed position, WARNING The following procedure uses trichloroethylene, which is a toxic solvent, Inhalation of its vapors or proronged contact with the liquid can Cause Serious injury or death, CAUTION In the following procedure, during removal of the Wa. 1 and No. 2 thrust chamber fue} intel manifold drain quick-disconnect cap, the quick-discunneet body nist not be allowed to turn since damage to the quick-digconnect body can resuit. d. Remove pressure cap from, and connect thrust chamber fuel jacket flushing system to, each thrust chamber fuel inlet manifold drain quick- disconnect, CAUTION In the following procedure, drain hoses must be monitored during flushing of the thrust chamber, If drainage is observed from either fuel high pressurc duci drain hoses, the cource of the f.uid must be deter- mined before proceeding, ©, Pressurize hydraulic control system to 1,550 150 psig. {. Turn on operational low-level LOX deme and gas generator LOX injector purge system, 3-104A/3-104B8 K- 3896-11 WARNING The following procedure uses tri- chlorocthylene, which is a toxie solvent. Inhalation of its vapors or prolonged contact with the liquid can cause Serjous injury or death, NOTE To accomplish proper flushing of the thrust chamber, trichloroethylene must remain in the thrust chamber for at least one hour during steps g through p uf this procedure is per~ formed at post-test, gf. Turn ou thrust chamber fuel jacket flush- ing systein, and fill thrust chamber fuel jacket to injector overfiow. Alluwoverflowto continue for 30 secunds. h. Turn off thrust chamber fuel jacket flush- ing system. 8 i. (Deleted) j. Pressurize thrust chamber fuet jacket purge system. k. Allow purges to flow until all heavy vapor ceases to be emitted from thrust chamber exit. 1. Depressurize thrust chamber fuel jacket § purge system. m. Kepeat steps g through 1 2 additional times, WARNING The following procedure uses tri- chloroethylene, which is a toxie Sulvent. Inhalation of tis vapors or prolonged contact with the liquid can cause Serious injury or death. ne Section HI Turn on thrust chamber fuel jacket fliu3h- ing system, and fill thrust chamber fuel jacket tu injector overflow. Allowoverflowto continue for 5 0, seconds minimutn. Disconnect thrust chamber fuel jacket flushing system from each thrust chamber fuel inlet manifold drain quick- disconnect. p. Attach a drain hose to eachthrust chamber fuel inlet manifold drain quick--disconnect. q. Turn off operational low-level LOX dome and gas generator LOX injector purge system. rT. exit manifold drain plugs, and instali drain tools Remove lockwire from thrust chamber from Fuel Drainage Kit G2037 at drain plug using gasket RD262-3001-0010 between tool and dzain plug adapter. Check that drain tool ex- tension hex wrench is extended outward when installing tool, and drain ports of tool are posi- tioned aft. Torque drain toul to 36-60 in-1b. &. t. extension hex wrench irto head of drain plug and Install drain hoses on tools, Open drain plugs by inserting drain toul rotating wrench counterclockwise. u. Turn on operational low- level LOX dome and gas generator LOX injector purge system. ve Pressurize thrust chamber fuel jacket purge system, and verify operation of purge by monitoring emission of vapor from thrust cham- ber. We Allow thrust chamber fuel jacket purge to flow for 3 minutes minimum and to continue until all vapors cease to be emitted from thrust chamber, Xx. Depressurize thrust chamber fuel jacket purge system. y- dome Depressurize operational low-level LOX and gas generator LOX injector purge system. Ze Depressurize hydraulic control system, Change Nu. 6~ 16 February 1970 3-105 r j Section Ml Paragraph 3,5.4A CAUTION In the following procedure, during installation of the No. 1 or No. 2 thrust chamber fuel inlet manifold drain quick-disconnect pressure cap, the quick-disconnect body must not be allowed to turn since damage to the quick-disconnect body can result, aa. Remove fuel drain hose frorn cach thrust chamber fuel inlet manifold drain quick- disconnect, Remove pressure caps from packaging, and install pressure cap on each quick-diseonneet, Torque pressure caps to 30-40 ft-lb, Safetywire pressure caps with Inconel Jockwire MS20995N, ab, Remove drain touls,. ac, Remove drain plugs, and reinstall plugs using new K-seals 12100AA3, Torque drain plugs to 6-12 ft-lb. Safetywire plugs with Inconel lockwire MS2Q995N, acA, Ketorque thrust ciramber retin manifold drain adapters to 47-53 ft-lb without replacing seal, Safetywire adapter with Inconel lockwire MS20995N, ad. Disconnect thrust chamber fuel jacket purge system from fuel jacket purge quick- disconnect on each fuel valve, Remove pressure caps from packaging, and ing.2ll pressure cap or each quick-disconneect, Torque pressure caps to 30-40 ft-lb. Safetywire pressure caps with Inconel lockwire MS20995N, adA. If thermal insulation is ing.alled, secure inswator 145510 as otined in para- graph 3,5,16, ae, Disconnect drain hose from each fuel high-pressure duct quick-disconnect, Remuye pressure caps from packaging, and inetall pressure cup un each quick-disconnect. Torque pressure caps to 30-40 ft-lb, Saleitywire pres- sure caps with Inconel lockwire MS20095N, af. Drain ignition monitor valve sense line (paragraph 3,5, 9) 3.5.44 ‘THRUST CHAMBER POST- FLUSH PNEUMATIC LEAK TEST AT_KSC, This procedure conlaing instructions for leak testing olnts invalidaled durtug the LOX dome and gas generator LOX injector flush and the thrust 3-108 Change No, 13 ~ 4 April 5072 R-3896~11 chamber fuel jacket flush except for the thrust chainber fuel inlet manifold drain quick- disconnects and the thrust chamber dame PURGE 1D port used during this test. a. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3,1A when performing this test. b. Install thrust chamber throat plug (paragraph 3,6, 15), ec. Remove pin and closure from hypergol manifold cartridge container inlet port WARNING The following procedure specifies drycleaning solvent, which is am- mable and must not be used near heat, sparks, or open flame. Inhalation of its vapors or prolonged contact with the liquid can cause serious injury, NOTE The method for applying lubricant is outlined in R-3896-3, d. Clean threads of hypergo!l manifold cartridge container inlet nort with drycleaning solvent (Federal Specification P-D-680}, Lubri- eate (Method A) threads with lubricant grease RBOQ140-012 (Rocketdyne). CAUTION When installing the hypergol system test tool into the hypergol manifold cartridge container Inlet port, extreme care must be used to prevent damage to the hypergol cartridge follower, ® The threads of the test tool cap must ve clean and free of nicks to prevent galling the threads of the cap and inlet port, e, Make sure that threads of teat tool cap are clean and free of nicks; then lubricate (Mcthed L) cap packing with FS1261 grease (Dow Corning Corp) and carefully insert hyper- §& vol system test too] 9021279, or equivatent, into hypergol mantfold cartridge container iniot § port, and screw cap (clockwlse) onty inet port until cap boltems. R-3896-11 f. Install an oxidizer-clean adapter incorpo- F rating a check valve and a unton AN815-8C in theust chamber dome PURGE 1B part, f 6g. Connect an external source of gaseous I nitrogen (MIL-P-27401), capable of being R regulated and monitored from 0-100 psig and H filtered through a 40-micron (or smaller) filter, to adapter of thrust chamber dome PURGE 1B sport, Attach filter as close as possible to engine attach point, h, Connect a monitor gage and bleed valve to quick-discuonnect of thrust chamber throat Bplug. CAUTION The gaseous nikrogen supply hose to the throat plug seal must be sup- ported to prevent the weight on the Seal valve stem from damaging the seal, A 64, Cornerct a source of gaseous nitrogen to 4 throat plug seal, Using a suitable matertal, J support the gaseous nitrogen suppiy hose to a reliove all weight of hose from seal valve stem. Procedure f jf. Pressurlze B throat plug seal te H 50 (+b, -10) psig, A Maintain pressure F during remaloder 4 of test, | ok, Slowly supply f gaseous nilrogen at 1944 psig to thrust KB chamber through § chamber dome @ PURGE 18 port, 4 61, 0 Apply leak- Ss iest compound B (MUL E- 25567) to thrust chamber ) dome purge ports ER PUNGE 1A, PURGE 4 23, PURGE 27, g NO, 3 PURGE, and A NO, 4 PUNGE and A to any other joint Result Thrust chamber throat plug seal 1s pres- surized, Thrust chamber ts pressurized, Monitor gage indlcaies 9+1 psig. No leakage is allowet, Section Of Procedure Result invalidated during the LOX dome and gas generator LOX injector flush and the thrust ecnamber fuel jacket flush. Record resulls. CAUTION The thrust chamber must be depres- surized as outlined in sfup8 m and n to prevent contamination of the engine oxidiver syste.n, m, Completely open hand bleed valve on quick-diseonnect of thrust chamber throat plug, Thrust chaniber pres- sure venta, n, Turn off thrust ehambher pressure pneuniatic SOUrce, Supply pressure to thrust chamber dew creases to zero, and monitor gage on thrust | chamber throat plug quick- disconnect tndicates zero, NOTE The method for applying lubricant Is outlined tn R-3096-3, o, Remove source of gaseous nitrogen and adapter from thrust chainber dome PURGE 1B port, Gubricate (Method A) plug with lubricant grease RBO140-012 (Rockeidyne) and {Method R) seal with lubricant grease RBOM4A-N12 Qtocketdyne}) or fluorinated ofl Kryfox 143A¢4 (Du Pont) and install plug and seal, Torque to 350 +15 in-ib, and record plug installation torque value. Safetywire plug with Inconel lockwire MS2Q995N, p. Remove monitor gage and hand bleed valve from quick-disconnect of thrust chamber throat plug. q. Depres*nrize thrust chamber throat plug seal, Chinge No, 13 - 4 April 1972 Be 106A Section M1 Paragraphs 3.5.5 to 3.5.8 four, Remove thrust chamber throat plug p (paragraph 3. 3,16), 8, Remove pin that secures hypergol test Pigol cap, and carefully unscrew cap and remove H tool from manifold, WARNING The following procedure specifies drycleaning solvent, which is flam- mabie and must not be used near heat, spavks, or open flame, Inhalation of its vapors or prolonged contact with the liquid can cause serious Injury. } t. Clean threads of hypergol manifold F cartridge container inlet port with dcycleaning H solvent (Federal Specification P-D-680), us Remove hypergol manifold cartridge f confainer inlet port closure frum packaging. R lubricate (Method L) closure packing witp ® FS1281 grease (Dow Corning Corp) and install B closure, Secure with attaching pin, WARNING The following procedure specifies cleaning compound (MIL-C.-81303), which is volatile. Use In 4 well- ventilated area eince the vapors displace the oxygen in the air, resultiig in suffocation. v. Remove all leak-test compound froin joints and ‘ittings with a clean, dry clath, or vy flushing, inancessible areas with cleaning compound (MIL-C-81302), 3.5.5 ENGINE RESIDUAL FLUID REMOVAL. NOTE Cmit steps a through c at KSC witesa engine Is to be removed froin slage or aiage 1s to be recycled through VAB, a, Remove section of thermal tneviation that covers turbine bearing thermocouple cover, b, Remeve turbine bearing the, mocouple access covec fran manifoid shivid, 3-106P Change No. 13 + 4 April 1972 R-3896-11 c. Using a suction pump, remove residual fluids from turbine manifold shleld (internal and external). If internal fluid ts evident, flush with water; then remove water with Suction pump, d. Using suctton pump, remove residual fluids from top of thrust chamber oxidizer dome, from area between thrust chamber oaldizer dome and thrust chamber fuel manifold, and from cavity at both fuel pump Inlet elbows at inlet to fuel pump, NOTE When thermal insulation ts installed, there is no access to cavity between No, 1 fuel pump inlet elbow at Inlet to fuel pump. ® Onut steps e and {at KSC unless en~ gine is tc he removed from stage or atage ia to be recycled througn VAB. e, Reinstall turbine hearing thermocouple access cover on turbine manifold shield, Torque cover boils to 60-80 in~Ib, f. Heinstall thermal insulation to thermo- couple access cover. Safetywire with Inconel lockwire MS20095N32, g. Remove residual fluids from exterior of engine. 3.5.6 AUMITTING PREFILL TO ENGINE, a, Perform, as applicable, contamination and damage prevention procedures outilned in paragraph 3,1A when perfcrming this procedure, NOTE Omit step b Lf engine fuel feed system la pressurized ta 2 psig minimum during this procedure, b, Remove pressure caps from, and install drain hoses on, the following quick-disconnects, R- 3806-11 (1) No. 1 fuel high-pressure duct drain (2) No. 2 fuel high-pressure duct drain c. If engine environmental cover is Installed, untie exit end of cover, roll cover clear of exit end of nuzw#le extension, and secure cover. d. ‘Turn on operational low-level LOX dame and gas generator LOX injector puige system. e. Admit prefill tluid, meeting requirements of section II, to thrust chamber fuel jacket until injector overflows, f. Monitor prefill system connections for leakage while admitting prefill fluid. No leak- age is allowable. ge. Turn off operational low-level LOX dome and gas generator LOX injector purge system. NOTE If the cngine is to be gimbaled after prefilling the thrust chamber fuel jacket, the operational low-level LOX dome and gas generator LOX injector purge system must be turned on before and during the gimbaling operation, and the thrust chamber must be topped off with prefill to the injector overflow subsequent to completion of the last gimba) operation. h. Monitor prefill fluid leakage from fuel overboard drain line. No leakage is allowable. NOTE Omit step i if engine fuel feed sys- tem was pressurized to 2 psig during the procedure. i. Disconnect drain hose from each fuel high- pressure duct quick-disconnect. Remove pres- sure caps from packaging, and install pressure cap on each quick-disconnect. Torque pressure caps to 30-40 ft-lb. Safetywire pressure caps with Inconel lockwire MS20995N. Change No, 13 - 4 April 1972 Section If Paragraph 3. 5.7 3.5.7 ADMITTING FUEL TO ENGIIE,. a. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3, 1A whenperforming this procedure. CAUTION In the following procedure, during removal of the No. lor No. 2 thrust chamber fuel in )et manifold drain quick-disconnect pressure cap, the quick-disconnect body must not be allowed to turn since dunage to the quick- disconnect body can result. b. Kemove pressure caps and install drain hoses at the following quick- disconnects and allow fluid to drain: (1) No. 1 thrust chamber fuel inlet mani- fold drain (2) No, 2 thrust chamber fuel inlet mani- fold drain c. Provide a suitable container for catching fluid; then remove gas generator combustor drain plug. If thermal insulation is installed, gain access to gas generator area by removing necessary lockwiring and screws at gas genera- tor insulator access door. (See figure 2-15. ) d. Continuously monitor gas generator ball valve and fuel valves for closed indication before, during, and after fuel is in fuel feed system. e. Admit fuel, meeting requirements of section If, to fuel feed system. NOTE Omit step fat KSC. f. Visually monitor fuel feed systero for external leakage. No leakage is allowable. g. During and after admitting fuel to fuel feed system, monitor drain hoses installed in step b for fuel leakage. Record fluid leakage from each drain hose. Maximum allowable leakage from each drain hose is 500 cc/m. Repeat inspection every 24 hours as long as drain hoses are installed. Leave drain hoses installed until last time access to engine arca is available, 3-106C/3-106D R-3806- 11 h, If no fue! leakage occurred in step g, omit steps i through m and proceed to step o. i. If fuel leakage occurred in step g, turn on operational low-level! LOX dome and gas gen- erator LOX injector purge, pressurize engine hydraulic control system to 415-1, 850 psig, and allow all fluid to drain from fuel inlet mant- fold. Monitor drain hoses for fuel leakage for one hour minimum. No leakage is allowable. j. If no fuel leakage occurred in step i, omit steps k through m; depressurize engine hy- draulic control system, turn off operational low-level LOX dome and gas generator LOX injector purge, and proceed to eteup o. k, If leakage was observed in step g, per- form thrust chamber fuel jacket drain (parg- graph 3.5.13), thrust chamber fuel jacket flush (paragraph 3.5.4), and admit prefill to engine (paragraph 3.5.6); then proceed to step 1. 1. Perform step b after a minimum of 1.5 hours with fuel in engine, and obtain samples of drained prefill solution. m. Visually verify that no fuel leakage exists in drained prefill solution. n. When it is verified that no fuel leakage exists in drained prefill solution, depressurize engine hydraulic control system and turn off operational low-level LOX dome and gas genera- tor LOX injector purge. o. Inspect for fuel leakage from gas genera- tor combustor drain port within one hour after fuel is admilted to engine. No leakage is allow~ able. Repeat inspection every 24 hours for as long as combustor drain plug is removed. Leave drain plug uninstalled until last time accegs to engine area is available. p. Monitor nitrogen purge overboard drain line at thrust chamber exit, for fuel leakage. No leakage ia allowable. q. Monitor fuel overboard drain Une at thrust chamber exit, for fuel leakage. Leakage in exceas of that recorded during hydraulic controi Section If] system leak and function teat requires isolation of overboard drain system components. Maxi- mum allowable component ieakage into fuel overboard drainage system is as follows: (1) Maximum aliowable leakage from redundant shutdown valve drain port is 2 cc/m. (2) Maximum allowable leakege fromm ignition monitor valve drain port is § cc/m. (3) Maximum allowable leakage from en- gine control valve override drain port is 5ec/m. CAUTION Yn the following procedure, during removal and installation of No. 1 or No. 2 thrust chamber fuel inlet manifold drain quick- disconnect pressure cap, the quick-disconnect body must not be allowed to turn since damage to the quick-discunnect body can result. x. Remove drain hoses from No. 1 and No, 2 thrust chamber fuel inlet manifold drain quick~ alsconnects. Remove pressure caps from pack- aging, and install pressure caps on quick- disconnects. Torque pressure caps to 30-40 ft-lb. Safetywire pressure caps with Inconel lockwire MS20995N. NOTE The method for applying lubricant in the following procedure is out- line? in R- 3896-3. 5s. Remove plug and K-seal from packaging. Lubricate (Method A)plug threads with thread co:npound C-5A (Felt Products), and inatall plug RD273- 6003-0004 and new K-seal 12100AA4 in combustor drain boss. Torque plug to 200-240 in-lb. Record actual torque value of plug. Safetywire plug with Inconel lockwire MS20895N. i. Reinstall thermal insulation, if re-uired. (See figure 2-15.) Torque screws to 22-28 in-lb. Safetywire screws with Inconel lackwire MS20095N40. Change No. 8 ~ 9 September 1970 4-107 Section Tif Paragraphs 3.5.8 to 3.5.10 u. Admit prefill fluid, meeting requir ements of section , to thrust chamber fuel jacket until injector overflows, 3.5.8 ADMITTING LOX TO ENGINE, a. Provide turbopump heater power to engine. b. Verify that turbopump LOX seal purge is turned on, (Purge must be maintained whenever LOX is in engine LOX feed system. ) ce. Verify that hydraulic control system is pressurized to 1, 450-1, 850 psig. (During and after admitting: LOX to engane, maintain hydrau- Jic pressure ab 1, 450-1, 850 psig. After admit- ting LOX to engine, maintain hydraulic tempera- ture within limits of section IT.) cd. Continuously monitor gas generator ball valve and oxidizer valve closed positions priar to, during, and after LOX is in engine LOX feed system. e. Admit LOX, meeting requirements of section Il, to LOX feed system. f. Monitor engine ambient temperature as outlined in section HW, and on engines with ther- mal insulation inslalled, maintain cocoon ambient temperature as outlined in section II, after admitting LOX to LOX feed system. g. Monitor No. 1 bearing temperature as outlined in section II, after admitting LOX to LOX feed system. h. Monitor oxidizer overboard drain line for g LOX teakage. No liquid leakage is allowable. # i. Monitor thrust chamber exit for LOX E leakage. No leakage is allowable. 3.5.9 IGNITION MONITOR VALVE SENSE 6 RG 2 a TE RT TE Sl A LINE DRAIN, a. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3.1A when performing this procedure, aA. Remove pressure cap from, and attach fuel drain hose to, quick-disconnect located on ignition momtor valve CONTROL, port. b. Allow all drainage to cease. ec, Disconnect fuel drain line from ignition monitor valye CONTROL port quick-disconnect, Remove pressure cap from packaging, and in- stall pressure cap on quick-disconnect. Torque pressure cap to 30-40 ft-lb, Safetywire pres- sure cap with Inconel lockwire MS20995N. 3.5.10 RESIDUAL FUEL DRAIN. a — a. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3, 1A when performing this procedure. 3-108 Change No. 9 - 2 December 1970 R-3866-11 aA. Use caution while draining fuel propellant feed system to prevent fuel spillage on other engine systems, b. Inspect engine and Surrounding area to make sure that no hazardous condition exists, c. Pressurize turbopump LOX seal purge system during performance of this procedure. d. Sce figure 3-11, and install fuel drain vent adapter on ball valve fuel inlet drain quick- disconnect as follows. (1) Verify that adapter is assembled as outlined in R-3896- 5, (2) Connect Stage-Contractor- supplied drain tubing to adapter. CAUTION During removal of ball valve fuel in- let drain quick-disconnect pressure cap, the quick-disconnect body must not be allowed to turn, since the in- stallation between the quick- disconnect and ball valve may loosen and cause leakage. (3) Provide countertorque on quick- disconnect body, and remove pressure cap from ball valve fuel inlet drain quick- disconnect. (4) (Deleted) (5) Position fuel drain vent adapter, orient- ing check valve avove horizontal on ball valve fuel drain quick-disconnect as shown in figure BALL VALVE PUERL [INLET DRAM QUICK DISCONNECT — FURL DRAIN VENT ADAP At ™ STAGE-CONTRACTOR- SUPPLIED DRAIN TUBING Fl L1.?A Se eannmnnsaunmnenensamnammmmnenaammannane een naneenanseieenan aad Figure 3-11, Fuel Drain Vent Adapter Installation R-3896- f1 é. Remove pressure cap from, and attach a fuel drain hose to, each of the following quick- disconnects: (1) Turbopump No, 1 fuel inlet elbow drain (applicable only on engines that do not have thermal insulation installed) (2) Turbopump No. 2 fuel inlet elbow drain (3) No. 1 fuel high-p.essure duct drain (4) No. 2 fuel high-pressure duct drain f. Allow residual fuel to drain. NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3, %. Remove fuel dvain vent adapter. Remove pressure cap from packaging, and install pres- sure cap on quick-disconnect. Torque pressure cap to 30-40 ft-lb. Safetywire pressure cap with Inconel lockwire MS20995N, On engines incorporating MD168 change, lubricate (Method A) threads of ball valve fuel inlet drain quick- disconnect with lubricant grease RB0140-012 (Rocketdyne), and install pressure cap, Torque pressure cap to 216-230 In-lb. Safetywire pressure cap with Inconel lockwire MS20995N, h, Remove all drain hoses. Remove pres- sure cap from packaging, and install pressure cap on cach quick-disconnect listed in step e. Torque 3/8-inch pressure caps to 30-49 ft-lb and 3/4-inch pressure caps to 70-75 ft-lb, Safetywire all pressure caps with Inconel lock- wire MS20095N, i. Depressurize turbopump LOX seal purge system. 3,5,11 FUEL FEED SYSTEM DRAIN. a, Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3.1A when performing this procedure, aA. Use caution when draining thrust chambe or fuel feed system to prevent spillage on engine. Section 10 Paragraph 3. 5,11 b. Verify that no hazardous conditions exist around engine or surrounding area. NOTE Steps c through e are omitted at MTF and KSC when performing drain im- mediately after stage rotation to vertical position. ce. Pressurize hydraulic contral system to 415-1, 850 psig. d, Turn on turbopunp LOX seal purge sys- tem. e. See figure 3-11, and install fuel drain vent adapler on ball valve fuel inlet drain quick- disconnect as follows: (1) Verify that adapter is assembled as outlined in R- 3896-5. (2) Connest Stage-Contractor- supplied drain tubing to adapter. CAUTION Duving removal of ball valve fuel in- let drain quick-disconnect pressure cap, the quick-disconnect body must not be allowed to turn, since the installation between the quick- disconnect and ball valve may loosen and cause leakage. (3) Provide countertorque on quick- disccunect body, and remove pressure cap from each valve fuel inlet drain quick-disconnect. (4) (Deleted) Change Nu. 8 - 9 September 1970 3-109 Section IM (5) Position fuel drain vent adapter, orient- ing check valve above herizontal on batl valve fuel inlet drain quick-discounect as shown in figure 3-~1t. f, Drain fuel upstream of fuel valves by re- moving pressure cap from, and attaching a fuel drain hose to, each of the following quick- disconnects: (1) ‘Turbopump No. 1 fuel inlet elbowderain {only applicable on engines that do not have thermal insulation installed) (2) Turbopump No. 2 fuel inlet elbow drain (3) No. 1 fuel high-pressure duct drain (4) No. 2 fuel high-pressure duct drain (5) Hypergol manifold drain g@ through n. (Deleted) o. Turn off turbopump LOX seal purge system, NOTE Lhe method for applying lubricant in the follow.ng procedure is outlined in R-3896-3. p. Remove fuel drain vent adapter, Remove pressure cap from packaging, and install pres- sure cap on quick-disconnect, Torque pressure zap to 30-40 ft-lb. Safetywire pressure cap with Inconel lockwire MS20995N. On engines incorporating MD168 change, lubricate (Method A) threads of ball valve fuel inlet drain quick- disconnect with lubricant grease RBO140-012 (Rocketdyne), and install pressure cap. Torque pressure cap to 210-230 in-lb, Suafetywire pressure cap with Inconel lockwire MS20995N. 3-110 Change No. 8 - 9 September 1970 R-~3896- 11 q. Removealldrain hoses. Remove pressure caps from packaging, and install pressure cap on each quick-disconnect letedinstep f. Torque 3/8-inch pressure caps to 30-40 ft-lb and 3/4- inch pressure eaps to 70-75 ft-lb. Safetywire all quick-disconnect pressure caps with Inconel lockwire MS20995N. CAUTION In the following procedure, during removal and installation af No. lor No. 2 thrust chamber fuel inlet manifold drain quick- disconnect pressure cap, the quick- disconnect bedy must not he allowed to tun since damage to the quick- ilisconnect body can result, NOTE Steps r through t must be omitted when performing drain immediately after stage rotation to vertical position. rt. Disconnect pneumatic system from each fuel inlet manifold drain quick-disconnect. Re- move pressure caps from packaging, and install pressure cap on each quick-disconnect. Torque pressure caps to 30-40 ft-lb. Safetywire pres- sure caps with Inconel lockwire MS20995N. s. Close drain plugs by rotating drain tool extension hex wrench clockwise. Torque drain plugs to 8-12 ft-lb. t. Remove drain tools. Safetywire drain plugs with Inconel lockwire MS20995N. R- 9896-11 3.6.12 GAS GENKBRATOP COMBUSTOR DRAIN. a. If thermal insulation is installed, attain access ty gas generator area by removing nec- essary lockwiring and screws at gas yenerator insulator access door. (See figure 2-15. ) aA. Perform, as applicable, contamination and damage prevention procedures outlined in paragraph 3. 1A when performing this proce- dure, b. Rerwove plug, and inspect and remove any obstruction in gas generator combustor drain port. Allow any residual fluid to drain from conbustor into a Suitable ecntamer, After residual fluid drainage, monitor port for leak- aye for 5 minutes. No leakage is allowable. NOTE The method for applying lubricant in the tollowing procedure is outlined in R-3896-3, c. .Remove plug and K-seal from packaging. § Lubsicate (Method A)plug threads with thread’ compound C-5A (Felt Products), and install plug RD273-6003-0004 and K-seal 12100AA4 in combustor drain boss, Torque plug to 200-240 in-lb. Record actual torque value of plug. Safetywire plug with Inconel lockwire MS20995N, d. Reinstall thermal insulation, if required. Torque screws to 22-28 in-lb. Safetywire screws with Inconel lockwire MS20995N40. Section TM Paragraphs 3. 5. 12 to 3.5, 13 3.5.13 THRUST CHAMBER FUEL JACKET DRAIN. #. Connect thrust chainber fuel jacket purge system, mecting requirements of section II, to fuel jacket purge quick-disconnect of each fuel valve, If thermal insulation is installed, gain aceess to fuel jacket purge quick-disconnect on No. 1 fuel valve by loosening insulator 145510 as outhned in paragraph 3.5. 16, b. Verify that hydraulic control system is pressurized to 415-1, 850 psig. ¢. Remove pressure caps and connect drain houses on the following quick: disconnects: (1) Ignition monitor valve CONTROI. port (2) Hypergol manifold drain CAUTION In the following procedure, during reinoval of the No, lor No. 2thrust chamber fuel inlet manifold quick-~ disconnest pressure cap, the quick- disconnect body must not be allowed to turn, since damage to the quick- disconnect body can result. (3) No. land No. 2 thrust chamber fuel inlet manifold drain Change No. 8 - 9 September 1970 3-111 Section HI Paragraph 3,5. 14 dad. insdall Fuct Drainage Kit G2037 as follows: (1) Remove digin plugs (4 places). (2) Install drain tools at each theust cham- ber drain port using gaske! P:D264- 3001-0010 between tool and drain plang adapter. Extend drain tool extension hex wrench outward and position dram ort of tool aft. Torque teols to 36-60 ins tb, (3) Install drain hoses on drain tool ports. (4) Open drain plugs by inserting drain tool extension hex wiench into head of drain plug and rotating wrench counterclockwise. 8 oc. Turn on operational low-level LOX dome and gas generator LOX injectur purge system, f. Pressurize thrust chamber fuel jacket purge system and flow purge unlit all fluids and vapors are expelled from thrust chamber exit, overboard drain lines, and drain hoses that were connected in steps ¢ and d. g. Depressurize thrust charaber fucl jacket purge system. — oh. ‘Turn off operational low-level LOX dome and gas generator LOX injector purge system. i. Disconnect thrust chamber fuel jacket purge system from quick- disconnects on each fuel valve. Remove pressure cans from pack- aging, and install pressure caps. Torque pres- sure caps to 30-40 ft-lb. Safciywire pressure caps with Inconel lockwire MS20995N, i iA. If thermat insulation is installed, secure insulator 145510 as outlined in paragraph 3. 5. 16. CAUTION In the following procedure, during installation of the No. lor No. 2 thrust chamber fuel inlet manifold 8 drain quick- disconnect pressure cap, the quick-disconnect body must not be allowed to turn, since damage to the quick- disconnect body can result, j} Disconnect drain hoses installed in step c. Remove pressure caps from packaging, install pressure caps on guick-disconnects. Torque pressure caps to 30-40 fl-lb. Safely wire pres- sure cans with Inconel leckwire MS20995N. k. Depressurize hydraulic control system if required, 3-112 Change No. 6- 10 February 1970 safety wire from thrust chamber Wt- 3896-11 1. Remove Fuel Drainage Kit G2087 as fol- lows; (1) Remove drain hoses from drain teols. (2) Remove drain plugs, and reinstall plugs using new K-seals L2100AA3, Torque plugs tuo 8-12 ft-lb. Safetywire plugs with Inconel lock- wire MS20995N. 3.5.14 THRUST CHAMBER FULL INLET MAN. IFOLD DRAIN, NOTE Omit step a unlecs fuc! valve leak- age has occurred without the hydrau- lic control system pressurized. a. Verily that operational low-level LOX dome and gas generator LOX injector purge is on and that engine hydraulic control system is pressurized to 415-1, 850 psig. aA. Perform, as applicable, contamination and daimape prevention procedures outined in paragraph 3, 1A whenperforming this procedure. CAUTION In the following procedure, during removal and installation of No. 1 or No. 2 thrust chamber fuel inlet mam- fold drain quick-disconnect pressure cap, the quick-disconnect body must not be allowed to turn, since damage to the quick-cdisconnect body can result, b. Connect a drain hase to each quick- disconnect on thrust chamber fuel inlet manifold, and drain all fluid from fuel indet tnanifold into clean sampling contamers,. c. Remove drain hoses from thrust chamber fuel inlet manifold quick-disconneets. Remove pressure caps from packaging, anc install pres- sure caps. Torque pressure caps to 30-40 ft-lb. Safetywire pressure zaps with Inconel lockwire MS20995N. d. Verify that no visible amount of fuel exists after prefill fluid settles in sampling container. R-3896- 11 3.5.15 TUREGPUMP PRESERVATION, 3.5.15. 1 Turbopump Preservation (Engines Not Incorporating HDI a5 Change). a. Verify that closures are removed from all overboard drain lines. 2A. Perform, as applicable, contamination and damage prevention procedures outlined in piragraph 3. 1A when performing this procedure, b, Provide a container (6 gallons minimum volume) to cateh fluid draining from overboard drain hnes. ce. Provide instrumentation for monitoring oxidizer pump bearing jet pre-.sure at tap LBIb as follows: (1) Disconnect static-firtug instrumenta- tion tube froma, or remove plug from tap LB1b, as applicable. (2) Connect a pressure page (0-400 psig) to tap LBIb. d. Kemove pressure cap from, and connect turbopump preservation servicing purge system, meeting requirements af section II,to bearing coolant control valve PRESERVATIVE IN port quick-disconnect. e. Turn on turbopump LOX seal purge sys- tem. Verify purge operation and that pressure is 80 +20 psig. f. Pressurize turbopump preservation sery- icing purge system to 28-45 psig, and purge turbopunp for 5 minutes. Monitor pressure at LOX pump hearing pressure tap LB1b. g. Disconnect turbopump preservation sery~ icing purge system from bearing coolant control yuiye PRESERVATIVE IN port quick-disconnect. h. Make sure preservation fluid has been thoroughly mixed and is at proper temperature, then connect the preservation system, meeting requirements of section II, to bearing coolant control valve PRESERVATIVE IN port quick- disconnect. i. Prepare to rotate turbopump shaft as follows: (1) Remove cap from torque-gear housing. (2) Using a 1-1/G6-inch-deep socket and a 2-foot extension, attach a 0-30 ft-lb torque wrench to torque-pinion-gear shaft. Paragraphs 3.5 CAUTION In the following procedure, exces- sive torque applied to the pinion-gear shaft can damage the turbopump. (3) To rotate turbopump shaft, depress lorque-gear-housing lockpin; then fully depress torque-pinion-gear shaft by applying pressure to torque wrench adapter, and slowly rotate turbopump shaft in one direction. Do not torque pinion-gear shaft in excess of 20 ft-lb. NOTE One revolution of the turbopump shaft requires 5 revolutions of the pinion- goar Shaft. js Turn on preservation fluid system, and preserve turbopump with 5 gallons minimum of preservation fluid at 200 425 psig. Monitor pressure at LOX pump bearing pressure tap LB1b, and visually check bearing coolant de- livery lines for leakage. No leakage is allow- able. NOTE A pressure differenual of more than 300 psig between the pressure enter- ing the bearing coolant control valve and the pressure on the gage installed at tap LB1b is an indication of a clogged bearing coolant control valve preservative filter, A clogged filter must be replaced as outlined in R-3896- 3. k. Rotate turbopump shaft continuously dur- ing preservation for a minimum of one complete revolution, 1. Discontinue turbopump shaft rolation, and allow preservation fluid to flow for 10 seconda; then turn off preservation system. m. Disconnect preservation system from bearing coolant control vaive, and reconnect preservation servicing purge system to quick- disconnect. n, Remove torque wrench, extension, and adapter from torque- gear housing. o. Verify that lockpin on torque~gear housing is fully extended and that torque-pinion-gear shaft is in lockout position. Change No. 6 - 10 February 1970 3-113 Section MI Paragraph 3. 5, 15.2 NOTE The method for applying lubricant in the following procedure is outlined in R- 3856-3. p. Lubricate (Method J ) packing with lubri- cant grease RBO140-012 (Rocketdyne); then install packing on torque- gear-housing cap. q. Lubricate (Method A) threads of torque- gear-housing cap with lubricant grease RBO140-012 (Rocketdyne); then install cap fingertight on tarque-gear housing. Safetywire cap with Inconel lockwire MS20995N. r. Allow turbopump to drain for 15 minutes ninimum, s. (Deleted) t. Pressurize turbopump preservation sery- icing purge systern to 25-45 psig, and purge turbopurap for 5 minutes. Re-preserve turbo- pump if, at anytime, purge pressure exceeds 50 psig. u. Disconnect purge system from bearing coolant control valve PRESERVATIVE IN port quick-digconnect. Remove pressure cap from packaging, and install pressure cap. Torque pressure cap to 30-40 ft-lb. Safetywire pres- sure cap with Inconel lockwire MS20995N, v. Turn off turbopump LOX seal purge system. w. Install closures on overboard drain lines. wA. Disconnect pressure gage from tap LB1b. Remove plugs from tube or plug and seal from packaging, as applicable. On engines not incor- porating MD103 and MD166 changes, lubricate (Method A) fitting and (Method G) static-firing instrumentation tube with lubricant grease RBO140-012 (Rocketdyne), and install tube. Torque tube coupling nut to 160 +10 in-lb. Safetywire coupling nut with Inconel lockwire MS20995N. On engines incorporating MD103 and MD166 changes, lubricate (Method A) plug, and install plug and seal in tap LBib. Torque plug to 40-65 in-lb, Safetywire plug with Inconel lockwire MS20995N. x. After each preservation, clean preserva- tion system between 4¢- micron filter and bearing coolant control valve ccnnection as outlined in R-3896-3, or {lush with propellant kerosene 3-114 Change No. 13 ~ 4 April 1972 R-3896- 11 (MIL- P- 25576) or RJ-1 (MIL- F-25558) fuel through a 40-micron filter, and purge with gaseous nitrogen (MIL-P- 27401) through a 40-micro” filter, 3.5.15.2 Turbopump Preservation (Engines Incorporating MDJ]45 Change, a. Verify that closures are removed from all overboard drain lines. b. Perform, as applicable, contamination and dumage prevention procedures outlined in paragraph 3. 1A when performing this procedure. ec. Provide a container (6 g.Jons minimum volume) to catch fluid drainage during preserva~ tion. d. Provide instrumentation for monitoring oxidizer pump bearing jet pressure at tap LBIb as follows: {t) Disconnect static-firing instrumentation tube, or remove plug from tap LBIb, as applicable. (2) Connect a pressure gage (0-200 psig) to tap LBlb. e. Remove pressure cap from, and connect turbopump preservation servicing purge system (meeting requirements of section II) to, bearing coolant control valve PRESERVATIVE IN port quick- disconnect. f. Prepare Scay nze Pump G2039 for operation, and connect pump to engine (see figure 3-11A) as follows: (1) Position pump by No. 2 side of engine. (2) Connect pump electrical plug to facility 115-vac, 60-cps outlet; then press pump RESET * switch. (3) Position tubing from pump outlet port and pump valve DRAIN port into container pro- vided in stepc. Make su-e tubing is routed so as to preclude restriction in tubing, and make sure exit ends of tubing are positioned in con- tainer so they will not be immersed in fluid. Secure tubing to prevent whipping of tubing. NOTE If tubing is kinked so that flow is re- stricted, resulting pressure buildup during preservation may unseat the turbine bearing seal and allow pre- servative fluid to enter the exhaust system. R- 3896-11 oy OT “ f “ & ft “Prater PERL DEAN re MEANT OU a? PIS PTO | i i t | an TYPICAL TIE AT NOZELE EXTENSION COVEH FLAP | “sn. FUEL OVERSOARD ACCESS FLAPS FOR DRA ACCE 3S DRAIN PORTS AND IGHITFRS (4 PLACES) — Fl ti-?2 SO IE SE AE A REL el Be rt em Figure 3-16. Engine Environmental Cover Installation Change No. 1 - 23 April 1969 3-123 Section IT Paragraphs 3.6.9 to 3.6.10 CAUTION In the following procedure, if a 12- point, l-inch deep-well socket is used to forque the igniters, the socket must fit loosely over the ig- niter shorting or shielding cap, to prevent damage to the shorting or shielding cap, NOTE A. shieiding cap must be used on ‘gniters at KSC during igniter installation and until igniter is connected, e. Check that gasket seats in recessed groove of igniter boss; then torque each igniter to 625 4265-in-Ib. f. Safetywire igniters with Inconel lockwire MS20995N. g. (Heleted) h. Remove shorting er shielding caps and connect nozzle extension igniter harness plugs P45 and P46 and gas generator igniter harness plugs P43 and P44 to igniters. Refer to R-3896-3 for electrical connzctors installation and removal, CAUTION Inert igniters must be removed and replaced with live igniters prior to jaunch. 3.6.9 LIVE IGNITER REMOVAL, a. Observe igniter handling safety require- ments of section TH, b. Disconnect clectrical connectors P43 and P44 from gas generator iguiters, Refer to R-3896-3 for electrical connectors installation and removal. ec. Disconnect electrical connectors P45 and P46 from nozzle extension igniters. Refer to R-3896-3 for electrical connectors installation and removal, d. Install shorting or shielding caps on igniters. NOTE A shielding cap must be used on ipniters at KSC after ¢ :niter harness is disconnected and until igniter is removed. ©, Remove gas generator and nozzle exten- sion Igniters, f. Package and store igniters as outlined in section JE, 3-124 Change No. 9 - 2 December 1970 R-3858-11 g- Remove plug and washer or gasket, as applicable, from packaging. Clean and inspect threads of plug ST39501Z2RKLGO1 for adequate silver plating. Replace plug if silver plating is not adequate, Instatl washer 651912-3 on plug. Do not lubricate plug. Install plug in gas gpen- erator igniter boss and torque to 600-650 in-Jb. Safetywire 2 igniter plugs together with Inconel lockwire MS20935N, As an alternate, plug MS9015~-08 with washer 651912-3 or gasket AN901-8C may be used. If washer 651912-3 is used, install plug MS9015-08 in igniter boss and torque to 150-200 in-ib. If gasket AN901-8C is used, screw plug MS9015-08 finger tight into igniter boss. Check that gasket seats in re- cessed groove on igmter bows. Torque plug to 150-200 in-lb, Safetywire plug with Inconel lockwire MS2Z0995N. h. Install protective clocures in nozzle extension igniter hosses, Se heen rr a. Disconnect electrical connectors P43 and P44 from gas generator igniters. Refer to R-3896-3 for electrical connectors installation and removal. b. Disconnect electrical connectors P45 and P46 from nozzle extension igniters. Refer to R-3896-3 for electrical connectors installation and removal, ec. Remoye gas generator and nozzle exten- sion igniters. d. Remove plug and washer or gasket, as applicable, from packaging. Clean and inspect threads of plug ST3$50122RKL001 tor adequate silver plating. Replace plug if silver plating is not adequate, Install washer 651912-3 on plug. De not lubricate plug. Install plug in gas gen- erator igniter boss and torque to 600-650 in-lb, Safetywire 2 igniter plugs together with Inconel lockwire MS20995N. As an alternate, plug MS9015-08 with washer 651912-3 or gasket AN90%-8C may be used. If washer 651912-3 is used, install plug MS9015-08 in igniter boss and torque to 150-260 in-Ib. If gasket AN901-8C is used, screw plug MS9015-08 fingertight into igniter boss. Check that gasket seats in re- cessed groove on igniter boss. Torque plug to 150-200 in-lb. Safetywire plug with Inconel lockwire MS20995N, dA. Install protective closures in nozzle extension igniter bosses. R-3896-11 e. Visually inspect each expended igniter to verify that igniter tube ig not separated from igniter body. If tube is separated from body, notify Rocketdyne representative, f. Store and dispose of expended igniter as outlined in section II, f3.6.10A HYPFERGOL CARTRIDGE SERVICING. 8 5.6.10A.1 Hypergol Cartridge Removal From i Container. “(See figure 3-16-[. ) a. Observe all safety precautions at using organization, and wear protective clothing specified in section II. B ob. Remove locking «ing, cover, and gasket f from each end of hypergo! cartridge shipping 4 container. ; c. Remove -3 cushions from cach end of f shipping container. d. Using 2 people, remove hypergol car- | tridge from shipping container as follows: : {1) First person hold shipping container f securely. (2) Second pergon reach into shipping | container from end opposite hypergol cartridge 8 cap and push -2 cushion and hypergol cartridge, fg asaunit, from shipping container sufficiently a to permit grasping of -2 cushion an] hypergol cartridge ot cap end. (3) Pull hypergol cartridge and -2 cush~ eB ion, as a unit, from shipping container, e. Unroll -2 cushion from around hypergol cartridge and remove hypergol cartridge in its polyethylene bag or bags if double-packaged. "NARNING The following procedures use clean- ing compound, which is volatile. Use ina well-ventilated area since the vapors displace the oxygen in the air, resulting in suffecation. {. If double-packaged, use a lint-free cloth moistened with cleaning compound idle cant a and wipe outer polyethylene bag ree of all visible contaminants; inspect bag for tearg then carefully open outer polyethylene i bag at hypergol cartridge cap end and remove iy perk: cartridge still sealed in inner po yethylene bag. Section II Paragraphs 3.6.10A to 3.6.10A.1 — —t————- LOCKING JUNG c5- COVER soe GASKE £ -t——--~ 3 CUSHION WYPER? OL wenn 2 CUSHION (SFALED IN 2 ene POLYE PIYLENE HAGS| SHIPPING CON TAIN Fp ern tie ! ‘ fom: | ¢ : ») tne COVER enter FOCKING RING GASKET FL-11-32 Figure 3-16-1. Hypergol Cartridge Packaging Change No. 7 - 28 April 1970 3-124A Section ff Paragraphs 3.6, 10A.2 to 3.6. 10A.3 g. Inspect polyethylene bag containing hyper- s gol cartridge for rips. If inner bag is torn # and outer bag was torn, remove bag and | restore hypergol cartridge to a serviceable F condition ag outlined in paragraph 3.6.10A.3, h, Before unsealing polyethylene bag, use a B lint-free cloth moistened with cleaning com- B pound (M{I.-C-81302) and wipe polyethylene # bag free of visible contaminants. i. Cut off sealed end of polyethylene bag, fF and carefully remove hypergol cartridge from A Dag. f 3.6.10A.2 Hypergol Cartridge Inspection. a. Observe all safety precautions applicable A at using organization, and wear protective A clothing specified in section I. b. Verify (by hand torquing in tightening direction) that hypergol cartridge is tight to its plug. : c. Inspect hypergol cartridge packings for § chipping, cracking, or improper fit. If pack- f ings are damaged, restore hypergol cartridge f toa ge.viceable condition ag outlined in para- Bo graph 3.6. 104.3. ad. Verify that downstream packing ring § (located between packing and cap in packing f groove) is not tucked under packing. 3.6,10A.3 Hypergol Cartridge Restoration. (See figure 3-16-32.) a. Observe alt safety precautions applicable f at using organization, and wear protective clothing specified in section I, when applicable. : b. Remove and discard packings and ring from hypergol cartridge. WARNING The following procedures use clean- ing compound, which is volatile. Use in a well-ventilated area gince the vapors displace the oxygen in theair, resulting in suffocation. c. Using a lint-free cloth moistened with cleaning compound (MIL-C-81302}, wipe hyper- — gol cartridge exterior, packing grooves, and outside of plug free of all visible contaminants. 3~ 12473 Change No. 7 = 28 April 1970 R-3096-11 PACKING MS29513-227 PACKING BS29513- 429 THI"G MS28783-6- sHown COMPRESSED) at B) FL1-11-33 Figure 3-16-2. Hypergol Cartridge Restoration d. Using a lint-free swab moistened with cleaning compound (MIL-C-81302), remove all visible contamination from interior of plug. e. Inspect threaded area of cap for contam- inants or lubricant. CAUTION In the followirg procedure, cleaning cornpound must not be permitted to contact the lubricated bearing surface between the cap and plug since the cleaning cornpound will remove the lubricant, f. If contamination or lubricant is detected during inspection of cap threads, use a brush or 4 lint-free cloth moistencd with cleaning compound {MIL~C-81302) and remove all visible contaminstion or lubricant from threeds. R-3896-11 g. Install a new ring MS28783-6 in packing groove closest to cap. NOTE The method for applying lubricant in the following pree dure is outlined in R-3896-3. h. Lubricate (Method L) packing MS29513-228 and packing groove closest to cap with FS1281 grease (Dow Corning Corp) and install packing with ring positioned in groove between packing and cap. i. Lubricate (Method L) packing MS29513-227 and packing groove farthest from cap with F$1281 grease (Dow Corning Corp) and install packing. NOTE There is no ring to be instelled in the groove with packing MS29513~-227. 3.6.10A.4 Hypergot Cartridge Weight Check. a. Observe ali safety precautions applicable al using organization, and wear protective clothing specified in section II. b. Remove protective packaging from hypergol ag outlined in paragraph 3.6.10A. 1. c. Weigh hypergol cartridge, and record weight. d. Compare weight recorded in step c with weight recorded on hypergol cartridge. Re- vorded weight must be within 15 grams of hypergol cartridge gross weight. e. Repackage hypergol certridge as outlined in paragraph 3.6. 10A.5. 3.6. 10A.5 Hypergol Cartridge Repackaging. (See figure S-16-L. a. Observe all safety precautions applicable at using organization, and wear protective clothings specified in section IL, b. Verify that hyper gol cartridge is free from contaminants and darrage. Section ITI Paragraphs 3.6.10A.4 to 3.6.10A.5 ec. Package hypergol cartridge in a clean bag rade from plastic sheet and strip (Federal Specification L-P-378, Type II). Fold top of bag closed and seal bag with pressure-sensitive tape RB0195-002 (Rocketdyne) or (Federal Specification PPP-T-60}), NOTE A clean polyethylene bag (Federal Stock No, 8105-LCO-6811) or poly- ethylene tubing (Federal Stock No. 8135-782-7460) heat sealed al one end, may be used instead of plastic sheet and strip, All polyethylene Inaterial used must be 0. 004-inch minimum thickness. d. Packaso the single-packaged hypergol cartridge in a second clean bag made from plastic sheet and strip (Federal Specification L-P-378, Type li), Fold top of bag closed and seal bag with pressrre-sensitive tape RBO195-00? (scocketdyne) or (Federal Specifi- cation PPP-T-60). NOTE A clean polyethylene bag (Federal Steck No. 8105-LCO-6811) or poly- ethylene tubing (Federal Stock No. 8135~782-7460) heat sealed at one end, raay be used instead of plastic sheet and strip. All polyethylene material uged must be 0. 004~-inch minimum thickness, e. Verify that hypergol shipping container and cushions are free fram moisture, {. Verify that shipping containe” is the orig- inaJ container for that particular henergol cartridge, g. Wrap double-packaged hypergol cartridge in -2 cushion and insert as a unit into shipping container with cap end of cartridge up when caution decal on container ig right side up. h. Install -3 cushions in shipping container at each end of hypergol cartridge. i. Install gasket, cover, and locking ring on each end of shipping container. Torque locking ring clamp screw gufficiently to seat cover on gasket. Change No. 8 - 9 September 1970 3-104 Section Il Paragraph 3.6. 11 3.6.11 HYPERGOL CARTRIDGE INSTALLA- TION, a. Perform,as applicable, contamination and damage prevention procedures outlined in paragraph 3. 1A when performing this procedure. NOTE The hypergol-cartridge~installed indication must be monitored through- out this procedure. aA. Remove pin that secures closure in hypergol manifold cartridge container inlet port; then remove closure. b. Observe all safety precautions applicable at using organization, and wear protective clothing specified in section II. bA. Remove hypergol cartridge from ship- ping container as outlined in paragraph 3.6. 10A.1. c. Verify that hypergo) cartridge weight check has been performed as outlined in paragraph 3.6. 10A, 4, ad. Perform hypergol cartridge inspection as outlined in paragraph 3.6. 10A. 2, e. (Deleted) f. Verify that hypergol-cartridge-installed switch is deactuated. NOTE The method for applying lubricant in the following procedure is out- lined in R- 3896-3. g. Lubricate bore of hypergel manifold cartridge container with FS1281 grease (Dow Corning Corp). (See figure 3-9.) h. Lubricate (Method A) threads of hypergot manifold cartridge container inlet port with F81281 grease (Dow Corning Corp). 3-124D Change No. 9 + 2 December 1970 R~-3896-11 i. Carefully insert cartridge into hypergol manifold cartridge container inlet witiout bind- ing, scuffing, or any irregular resistence that indicates an incorret size packing or a damaged hypergol container. j. Serew hypergol cartridge cap clockwise onto container until hole in cap alines with hole in container. Verify that hypergol cartridge switch actuates. WARNING {n the following procedure fluid leak- age from a damaged hypergol can result in serious injury to personne} und dgmage to equipment. k. If electrical verification that hypergol cartridge is installed cannot be obtained, clear immediate area. Disarm an installed hypergol cartridge as outlined in paragraph 3.6. 12.1. R-3896-11 Section Il Paragraphs 3.6.12 to 3.6.12.1 CAUTION e. Turn on operational high-level LOX dome and gas generator [.OX injector purge system, In the following procedure, using and audibly verify operation of purge. force to install the hypergol car- tridge cap on the container can f. Pressurize thrust chamber fuel jacket Tesult in damage to the container purge system to 350 +50 psig, and cartridge. 1. Do not use a tool to install hypergol car- WARNING tridge cap on container. If hole in cartridge gap cannot be alined with hole in container, In the following procedures, the test remove cartridge and take corrective action. area must be cleared until the hy- pergol cartridge diaphragms have m. Insert pin through alined holes, securing burst and hypergol fluid has been Cap on container, until pin lo. xs in place. purged from the container since an explosion and fire can occur, re- 3.6.12 HYPERGOL CARTRIDGE REMOVAL. sulting in serious injury to personnel reg he ie eg a eee eng ga and damage to equipment. WARNING g. Pressurize igniter fuel valve lockup No attempt must be made to remove purge to 750 425 psig. a live hypergol cartridge if damage to the cartridge diaphr.igm is sus- pected since a fire can occur, resulting in serious injury to per- sonnel and daraage to equipment. h. Slowly pressurize hypergol malfunction purge system until hypergol cartridge di.- phragms burst. i. Allow purges to continue until all vapor j 7 7 t. 3.6.12. 1 Liye Hypergol Cartridge Removal ceases to be emitted from thrust chamber. When Dama S ted. : When Damage is Suspected, j. Depressurize hypergol malfunction purge syctem. a. Perform, as applicable, contamination ss dal and damage prevention procedures outlined in paragraph 3. 1A when performing this k. Depressurize igniter fuel vaive lockup procedure. purge system, and bleed pressure from igniter fuel valve cap. aA. Observe all safely precautions applicable at using organization, and wear protective 1. Depressurize thrust chamber fuel jacket clothing specified in section I. purge system. b. Remove pressure cap from, and connect m. Turn off operational high-level LOX hypergol malfunction purge system, meeting dome and gas generator LOX injector purge. requirements of gection II, to, hypergol purge quick-disconnect. n. Disconnect igniter fuel valve lockup purge system from igniter fuel valve vent port, c. Remove pressure cap from, and connect and reinstall igniter fuel valve drain tube as thrust chamber fuel jacket purge system, follows: meeting requirernents of section H, to, fuel jacket purge quick-disconnect on each fuel (1) Remove plug from igniter fuel valve valve. drain tube. d. Disconnect igniter fuel valve drain tube from, and connect a source of gaseous nitrogen, meeting igniter fuel valve lockup requirements of section II, to, igniter fuel valve vent port, Change No. 7 - 28 April 1970 3-125 Section ITT R-3696-11 Paragraphs 3.6,12.2 to 3,6.12.3 NOTE ad, Wipe excess lubricant from hypergol car- The method lor applying lubricant in tridge packings and from exterior of cartridge. the following procedure is oullined ce, Repuckage hyperyol cartridge a6 outlined in R- 3896-3. in paragraph 3,6. 104.5, {2) Lvbricate (Method A) filling and WARNING (Method G) igniter fuel valve drain tube with The followi a ‘ d lubricant grease 9140-012 (Rocketdyne). SOE NS BrOnSi iy CRMae Eby cleaning solvent, which is flammable (3) Install igniter fuel valve drain tube and must not be used near heat, sparks, and torque tube coupling nut vo 270-345 in-lb, or open flame, Inhalation of its vapors or prolonged contact with the liquid a. Disconnect tarust chambev fuel jacket : ; ean cause Serious injury, purge system from fuel jacket purge quick- disconnect on each fucl valve. Remove pres- f, Clean bore of hypergol manifold cartridge sure cap from packaging and install pressure container with dryc’eaning solvent (Federal ap On quick-disconnect. ‘Torque pressure Specification P-1-680), Wipe bore dry with a cap to d0-40 ft-Ib. Safetywire cap with clean, dry, lint-free cloth, Inconel locwire MS20895N. : g. Clean tureads of hypergol manifold car- p. Disconnect hypergol inalfunction purge tridge container inlet port with drycleaning system from hypergol purge quick-cisconnect. solvent (Federal Specification P-D-680), Remove pressure cap from packaging: and NOTR install presgure cap on quick-uwisconnect. ‘ ‘Vorgue pressure cay to 30-40 ft-lb. Safetv=- The method for applying lubricant in wire cay with Inconel lockwire MS20905N. the following procedure is outlined in R- 3896-3, q.- Rennve expended cartridge as outlined in paragraph 3,6, 12.3. GA. Lubricate (Method L) closure packing with FS1281 grease (Dow Corning Corp). h. Install hypergol cartridge inlet port clo- 3.6.12.2 Live Hypergol Cartridge Re ; : dive Hypercel Gavtrldge Removal sure an‘ secure with attaching pin. When No Damage it, Suspected, a. Perform, as applicable, contamination 3,6.12.3 Expended tiypergol Cartridge Re~ and damape prevention procedures outlined in movil, paragraph 3.1A when performing this a. Perform, as applicable, contamination procedure, and damage prevention procedures outlined in cuble at uging orgenization, and wear WARNING srotective clothing: specified in section II. } & SI ts No attempt must be made to i‘umove aB. If white smoke is evident at hypergo} a live hypergol cartridge if damage manifold, agsume that hypergol cartridge is to cartridge diaphragms is suspected damaged ang perform paragraph 3.6. 12. 1. since a fire can occur, resulting in serious injury to personnel and b. Remove pin that secures hypergol car- damago tc equipment. tridve in cartridge container inlet port. WARNING aA. Observe all safety precautions appli- cable at using organization, and wear protective In the following procedure, if there clothing specified in section II. is any evidence of white smoke during removal of cartridge, the NOTE area must be evacuated immediately since a fire could result, causing serious injury to personnel and damage to equipment. The procedure for disarming an in- stalled live hypergol cartridge is outlined in paragraph 3.6.12.1, ec. Urserew hypergol cartridge cap from con- b. Remove pressure cap from, and connect tainer; then carefully remove cartridge from a drain hose to, hypergol raanifold drain quick- container, disconnect. 3-128 Change No, 8 - 9 September 1970 R- 3856-11 ec. When al) fuel ceases to drain from hyper- gol cartr dge, disconnect drain hose, remove pressure cap fiom puckaging, and install pres- sure cap on hypergol cartridge drain quick- disconnect. Torque pressure cap to 30-40 ft-lb. Safetywire cap with Inconel lockwire MS26995N. d. Remove pressure cap from, and connect hy: wol servicing purge system, mecting re- qu. cents of section I, to, hypergol pure qui ..- disconnect, e. Turn on operational high-level LOX dome and gas generator LOX injector purge system, and audibly verify operation of purge. f. Pressurize hypergol purge system to 150 450 psig, and audibly verify operation of purge. After purging 3 minutes minimum, depressurize purge system. r- Turn off operational high-level LOX dome and gas generator LOX injector purge system. h, Remove pin that secures cartridge in hy- pergol manifold cartridge container inlet port. i. Unscrew hypergol cartridge cap from container; then remove and place cartridge in its shipping container. WARNING The following procedure uses drv- cleaning solvent, which is Mammable and must notbe used near heat, sparks, or open flame. Inualation of its vapors or prolonged contact with the Nquid can cause serious injury, j. Clean threads cof hypergol manifold car- tridze container inlet port with drycleaning solvent (Federal Specification P-ID-680). NOTH The method for applying lubricant in the following p: ocedure is outlined in R-3896-3, jA. Lubricate (Method L) closure packing with F31281 grease (Dow Corning Corp), k. Install hypergol cartridge inlet port clo- sure and secure with attaching pin. i, Disconnect hypergol servicing purge sys- tem, remove pressure cap from packaging, and install pressure cap on hypergol cartridge con- tainer purge quick-disconnect. Torque pres- sure cap to 30-40 ft-lb. Safetywire cap with Inconel lockwire MS20995N. Section IN Paragraphs 3,6. 13 to 3. 6. 14 3.6.13 THRUST CHAMBER THROAT SECU- a — RITY CLOSURE INSTALI LALLATION, a. If installed, remove thrust chamber cuail closure and thrust chamber throat closure. b, Obtain shaft from Thrust Chamber Throat Security Closure G4v089; then retract pin and secure in detent position. c. Install shaft in center hole of thrust chain- ber injector until siiatt bottoms, aline pin be- tween extensions on injector face, and then release pin from detent position. NOTE In the following procedure, desiccant must not be removed from its airtight container until just prior to installa- tion. d. Instali 48 units of desiccant as outlined in section II in cover ef closure, and make sure humidity indicator 3s in safe range. é. Install closure on shaft. Aline hole in closure extension with hole in shaft, and install combination padlock 9026900 through closure and shaft. f. Inflate closure tune to 5-7 psig pressure vith gaseous nitrogen (MIL-P-27401). g Reinstall thrust chamber exit closure, if applicable. 3.4.14 THRUST CHAMBER ‘THROAT. SECU- RITY (TY CLOSURE E REMOVAL, a. Remove thrust chaniber exit closure, if applicable, b. Remove padlock, deflate closure, and remove thrust chamber throat security closure. c. Place pin in decent position, and remove shaft, Change No. & - 9 September 1970 3-127 Section Ii Paragraphs 3.6.15 to 3.6.16 ad. Romove desiccant from closure, and store desiccant ag outkined in section I. e. Package thrust chamber gecurity closure for storage by enclosing it in a clean plastic bag, then cushioning it with polyurethane mate- rial in a suitable box, 3.6.15 THRUST CHAMBER THROAT PLUG INSTAI LATION. a. Clean threaded hole in center of thrust chamber injector prio. to installing throat plug. NOTE The method for applying lubricant in the following procedure is outlined in R-3896-3. b. Lubricate (Method A) threads of throat plug shaft with lubricant grease RBO! 40-012 (Rocketdyne). CAUTION In the following procedure, the spacer must not be allowed to bottom against the shaft collar, since damage to the injector may result. c. Install spacer on shaft. Holding spacer galngt thrust chamber injector, serew shaft ino thrust chamber injector while monitoring that clearance is maintained belween spacer and shaft collar. d. Measure axial spacing between spacer and shart collar. Allowable spactng is 0. 020 to 0.02% duch. NOTE If spacing is less than 0. 020 inch, perform steps ¢ andf. If spacing is proater than 0.020 inch, proceed lo step ¢. «. When spacing is less than 0.020 inch, un- nerow shaft from injector and ingert washer T- 5046431 over shaft threads; then holding spacer against thrust chamber injector, screw shaft into thrust chamber injector. Monitor that clearance is maintained between spacer and shaft collar, f. Measure axial spacing between spacer and shaft collar. Allowable spacing with washer T-50460431 installed is 0.020t 0.274 inch. g. Torque shaft to 500 450 in-lb. h. Apply petrolatum (Federal Specification VV-P-236) to tubes in thrust chamber throat. 3-128 Change No. 11 - 6 May 1971 R-3896-11 4. install support on shaft, alining support keyholo slot with shaft pin; rolate support clockwise to lock. CAUTION In the following step, care must be taken when installing the seal, to pre- vent damaging the seal stem. j. Make sure that seal is clean, and install seal on support with valve stem facing outboard and ridges of seal periphery alined withtube contours. k. Install retainer on shaft, alining retainer keyhole slots with studs on support, and rotate retainer clockwise to secure. 1. Install washer and nut on shaft and tighten firmly, Make sure washer contacts retainer. mn. Install quick-disconnect and burst dia- phragm in support. CAUTION In the following step, the gaseous nitrogen supply hose must be sip- ported to prevent the weight on the scal valve stem from damaging the seal, mA, Connect a source of gaseous nitrogen to throat plug seal. Using a suitable material, support the gaseous nitrogen supply hose to relieve all weight of hose from seal valve stem. Result n. Pressurize throat Thrust chamber throat plug seal to §0 (+5, -10) plug seal is pres- psig. Maintain pres- surized, sure during reinatnder of test, Procedure REMOVAL, - " a, Verify that pressure is yented from thrust chamber. b. Verify that thrust chamber throat plug seal is depressurized, ec. Remove quick~-disconneet and burst dia- phragm from retainer. d. Remove nut and washer from shaft. e. Rotate relainer counterclockwise on shaft to aline retainer keyhole slots with studs on Support, and remove retaiier. R-3896-11 f, Rotate support counterclockwise, alining support keyhole slot with shaft pin, and remove support. CAUTION In the following step, care must be taken when removing the seal, to prevent damaging the seal stem. fA, Carefully remove seal from support. g. Unserew shait from injector, and remove spacer from shaft. WARNING The following proeedure uses tri- chloroethylene, which is a toxic solvent. Inhalation of its vapors or prolonged contact with the Hquid can cause injury or death. h. Wipe thrust chamber throat and throat plug seal free of petrolatum with a clean, lint- free cloth moistened in trichlorocthylene (MIL-'T-27602), i. Install thrust chamber throat securily closure (paragraph 3.6, 13). 3.6.17 TURBINE EXHAUST EXTE PRESSURE TEST FIXTURE INSTALLATION. a. Apply a thin coat of petrolatum (Federal Specification VV-P-236) to ends of all segment seals where they overlap. b. Remove knurled thuinbnuts from internal wrenching serews on each clamp. c. Attach one ciamp, with quick-release pin, to any lug on inner wall of thrust chamber exit. Omit 3 lugs and attach a second clamp, with quick-release pin, to fourth lug in either direction from first clamp. d. Place segment on thrust chamber, and aline holes in segment with 2 clamps. e. Insert internal wrenching screws through holes in thrust chamber exit ring, segment, and clamp. Altach knurled thumbnuts to inter- nal wrenching screws. Do not tighten. f. Aline outer curvature of segment with curvature of thrust chamber exil ring. Hand- tighten the 4 thumbnuts. g. To install segments No. 2 through 7, repeat steps b through f, proceeding clockwise. Section III Paragraphs 3.8.17 to 3.6.18 h. Yo install segment No. 8, loosen thumb- nuts on first segment installed and repeat steps L through f. NOTi The tapered seal on the end of seg- ment No, 8 must be placed under segment No, 1, i. Adjust alinement of all segments, as necessary. j. Install previously omitted clamps, Hand- tighten all knurled thumbnuts. k, Inflate each seal using paseous nitrogen (MIL-P-+27401) to 35 £2 psig, proceeding clockwise, NOs To determine if individual seals have inflated, a visual check must be made that ruber of scai has expanded to mect overlapping backup plate ofthe junction of each segment. 3.6.18 ‘TURBINE EXHAUST EXIT PRESSURE, TEST FIXTURE REMOVAL. a. Depressurize each segment seal at thrust chamber exhaust exit. bh. Remove knurled thtmbnuts that secure clamps, and remove seal seginentys from thrust chamber exit. WARNING The following procedure uses dry- cleaning solvent whichis flammablic and must not be used near heat, sparks, or open flame. Inhalation of ita vapors or prolonged contact with the liquid can cause serious injury. ec. Clean thrast chamber exit flange and flange boltholes of residual lubricant with dry- cleaning soivent (Wederal Specification P-T)- 680). Change No. 9 - 2 December 1970 3-129 Section III Varagraphs 3. 6. 19 tu 3.6. 21.1 3.6.19 INTERFACE PANEL ACCESS DOOR REMOVAL. Remove 60 screws that secure cach interface panel access door, and remove access doors, 3.6,20 INTERFACE PANEL ACCESS DOOR INSTALLATION. Install access doors on in- cerface panel using 60 screws for each door. Torque screws to 30-40 in-{b. 83.6.20A FUE, INLET ELBOW INSULATION ——- Eee gchar aor cree reer tale ers BOOTLINSTALLATION. (See figure 3-16A. ) NOTE The installation of insulation boots is identical for the No. land No. 2 sides of tne enyine. a. Position each half of insulation boot around fue! inlet duct between interface panel and fuel inlet clbow, b. Abhne boot haives, and secure halves together with snap fasteners provided. t. Secure insulation boot to interface panel flange and to fuel inlet elbow flange with boot clamps provided. Torque clamp screws to 20 +2 in«'b, 3.6.21 TARUST CHAMBER NOZZLE EXTEN- SION RE REMOV: AL, Me a. Verify that overbuaid drain Hines are removed (paragraphe 3. 6.21.1 and 3. 6. 21. 2). b. Verify that igniter harness is removed (varagraph 3.6.4). c. Posttion Engine Vertical Installer G4049 under nozzle extension, and raise installer until extension is seated in installer (6:1 ring. d. Disconnect extension from thrust cham- ber. e. Lower extension, and position installer clear of engine. 3-130 Change No. 6 - 10 February 1970 R-3896- 11 Le, aa 3 a eS 4 SS INSL LATION PANEL AS sVEL INLETS EL OW eer Ve Figure 3-16A. Fuel Inlot Elbow Insulation Bout Installation LYPICAL ENSTALI ATION ue ~ Oh cams iy Gs) + Se rG | io te OX. SNAP » hee of by — red ‘FASTENERS al Ee a : Rei (TYPICAL! BOO) C1 AMR? ; a CLYPICAL) , 7 ke SN, INTPREACE San ace /_ PANEL 3.6.21,1 Fuel Overboard Drain Line Removal. a. Remove attaching hardware that secures cushion clamps to nozzle extension (figure 3-14, view C-C). Retain attaching hardware for rein~ atallation, if acceplable fer reuse in accordance with requirements of section IL. b. Remove attaching hardware that secures fuel overboard drain line, and remove seal plate. Retain attaching hardware for reinstal- lation, if acceptable for reuse in accordance with requirements of section II, ec. Install cover on overboard drain. R-3896-11 3.6,21.2 Oxidizer zer Overboard Drain Lit Line and Nitrogen Overboard Drain Line R Removal. — a. Remove attaching hardware that secures cushion clamps to nozzle extension (figure 3-14, view A-A), Retain attaching hardware for vein- siallation, if acceptable for reuse in accordance with requirements of section I. b. Disconnect and remove nitrogen purge overboard drain line from union. ce, Remove attaching hardware that secures oxidizer overboard drain line, and remove seal plate. Retain attaching hardware for reinstal- lation, if acceplable for reuse in accordance with requirements of section Hf, d. Install cover on oxidizer overboard drain line and at thrust chamber exit. 3.6.22 ENGINE REMOVAL, 3,6.22.1 Horizontal Engine Removal, a. Provide support for wrap-around ducts and hoses. aA, Perform, as applicable, contamination and damage prevention procedures outlined paragraph 3.1A when performing this test. bh, Diseonnect wrap-around ducts and hoses from stage. CAUTION Care rnust be taken to prevent fluid spillage on engine when hydraulic supply and return Mnes are discon-~- nected. c, Disconnect pressure switch checkout line from interface panel fitting, d. Disconnect electrical interface connections. Change No, 14 ~ ® October 1972 Section Til Paragraphs 3.6. 21.2 to 3.6.22. 1 e. Disconnect ducting from oxidizer and fuel inlets as follows: WARNING Compressed gas must not be used for drying or cleaning unless effective chip guarding is used and personal protection equipment is worn, (1) Using low-pressure (less than 30 psig) gaseous nitrogen (MIL-P-~27401) or clean, dry air conforming to cleanness and humidity requirements of MIL-P-27401, blow oxidizer and fuel inlet flanges free of accumulated loose contaminants (water, sand, ete), WARNING The following procedure uses tri- chloroethylene, which is a toxic solvent, Inhalation of its vapors or prolonged contact with the liquid can cause serious injury or death, (2) Using a clean, lint-free cloth moistened in trichloroethylene (MIL-'T- -27602), wipe flanges free of all visible contaminants (carbon, etc). {3} Disconnect ducting from oxidizer and fuel inlets, and remove moisture from inlet flange fastener holes. f, Using Stage-Contractor-supplted horizon- tal engine installer, support weight of engine. 3~130A/3-130B R-3896-11 g. Disconnect gimbal actuators (vutboard engines) or stiff-arme (inboard engine), as applicable, h. Remove gimbal bearing cover, i. Remove fasteners from gimbal bearing to stage interface, j. Install Gimbal Bearing Locks G4049 (figure 3-12) and gimbal bearing cover. k. Carefully remove engine from stage area and install on Engine Handler G4069. Refer to R-3896-3 for instalation information. 1. Install closures on turbopump oxidizer and fuel inlets as follows: (1) On engines not incorporating MID161 change, install oxidizer inlet closure, On en- gines incorporating MD161 change, install ox!- dizer pump inlet test plate 9020163 incorporating captive fasteners and dust cover. Torque plate fasteners to 330-430 in-lb, (2) On engines not incorporating MD161 change, install fuel inlet closures on No, and No. 2 fuel inlets. On engines incorporating MD161 change, install outLoard fuel inlet test plates 9020162 incorporating captive fasteners and dust covers. Torque plate fastenerg to 120-155 in-lb. m. Remove wrap-around ducts and hoses. Verify that hydraulic supply and return ducts are full of Hquid when cover plates are in- stalled on ducts. Fill ducts with fluid that ments requirements of section I1,if necessary. n. When Stage-Contractor-supplied horizon- tal installer ls removed from engine, install thrust chamber throat security closure (para- graph 3.6.13). 3.6,22.2 Vertical Engine Removal, a, Remove thrusl chamber nozzle extension (paragraph 3,6, 21). aA. Install protective covers and closures on all engine systems as disconnects and removals are mad«. b. Remove wrap-around ducts and hoses, Verify that engine hydraulic supply and return ducts are fulloffluld when cover plates are installed on ducts. Fill ducts, if necessary. ec. Nisconnect pressure switch checkout line from interface panel fitting. Section [IT Paragraph 3, 6, 22.2 d. Disconnect electrical interface connections, e, Disconnect ducting from turbopur..p oxidi- zer and fuel inlets as follows: WARNING Compressed gas must not be used for drying or cleaning unless effective chip guarding is used and personal protection equipment is worn, (1) Using low-pressure (less than 30 psig) gaseous nitrogen (MIL-P-27401) or clean, dry air conforming to cleanness and humidity re- quirements of MIL-P-27401, blow ducting to turbopump oxidizer and fuel inlet flanges free of accumulated loose contaminants (water, sand, etc), WARNING The following procedure uses trichloroethylene, which is a toxic solvent. Inhalation of its vapors or prolonged contact with the liquid can cause serious injury or death. (2) Using a clean, lint-free cloth moistened in trichloroethylene, wipe flanges tree of all visible contaminants (carbon, ete), (3) Disconnect ducting from turbopump oxidizer and fuel inlets, and remove moisture from inlet flange fastener holes, (4) Separate ducting from oxidizer and fuel inlets, and cover inlets with Acsar No, 38C film (0, 002~inch minimum thicknesg) (Allied Chemical Corp). Secure film with pressure-sensitive tape RBO195-002 (Rocketdyne). f, Position Engine Vertical Installer G4049 beneath engine, and raise table until 10:1 ring of installer just seats against thrust chamber ring. g. Install tiedown cables to turbopump mounts, h. Disconnect gimbal actuators (outboard engines) or stiff-arms (inboard engine), and connect tiedown cables to girnbal actuator struts. Change No, 14 - 9 October 1972 3-131 Section OI Paragraphs 3.6.23 to 3.6. 23.1 i. Remove fasteners from gimbal bearing to stage interface. j. Carefully lower installer table, jA. Remove film from, and install closures on, turbopump oxidizer and fuel inlets as fol- lows: (1) On engines not incorporating MD161 change, install oxidizer inlet closure. On” en- gines incorporating MD161 change, install oxidizer pump inlet test plate 9020163 incorpo- rating captive fasteners and duct cover. Torque plate fasteners to 430-430 in-Ib. (2) On engines not iucorporating MD161 change, install fuel inlet clogures on No. 1 and No. 2 fuel inlets. On engines incorporating MD161 change, install outboard fuel inlet test plates 9020162 incorporating captive fasteners and duct covers. ‘Torque plate fasteners to 120-155 in-Ib. k. Install gimbal bearing cover. 1, Connect a turbopump LOX seal purge sys- tem to engine and pressurize lo 80 +20 psig. m,. Remove engine from stage. n. Install 4 Gimbal Bearing Locks G4059. (See figure 3-12.) o. Do not rotate level of fuel pump above level of oxidizer pump unt{l steps p and q have been performed. CAUTION Rotating level of fuel pump ahove level of oxidizer pump at this time can cause contamination. p. During engine rotation from vertical to horizontal position, supply gaseous nitrogen (MIL-P-27401) at 80 +20 palg to engine turbo- pump LOX seal purge interface. q. Allow purge to flow for 30 miiutes mini- mum after engine rotation from ve -tical to hor!zontal position. r. Depressurize turbopump 7,OX seal] purge system. 8. Install engine on air transport engine han- dler ag outlined in R-3896-3. 3-132 Change No. 7 - 28 April 1970 R-3896-11 3.6.23 FUEL OVERBOARD DRAIN SYSTEM ISOLATION, 3.6.23.1 Preparing Drain System for Isvlation, a. Provide containers (one gallon minimum volume) for catching residual fluid when per- forming the following procedures. b. Disconnect cross-to-lateral dram tube from Y-fitting on fuel overboard drain line. Drain residual fluid into a container. Measure and record volume of fluid collected, c. Loosen 2ross-to-lateral drain tube con- nection at cross. Rotate tube to clear Y-fitting on fuel overboard drain line, and retorque tube- to-cross to 900-500 in-lb. d. Install clean bags mide frem plastic sheet and strip (Federal Specification L-P-378, Type II) (one gallon minimum volume) ou open cross- to-lateral drain tube and on open Y-fitting on fuel overboard drain line as follows: (; 3 ure 5-168, ) (Seb. Og NOTE Clean polyethylene bags (Federal Stock No. 8105-LCO-6811) 12 by 18 Inches, or clean polyethylene tubing {Federal Stuck No. 8135-782-7460) 7-1/2 inches wide, cut to one-gallon minimum volume and heat seated at one end, muy be used instead of plastic sheet and strip. All poly~ eth: ‘one material uged must be f& 04 inch thick. (1) insert open end of bag over tube or fitting. Pleat bag around tube or fitting, and secures bag to tube or fitting with Airtex 217 tying tape, ‘I'ype II (Eon Corp), or equivalent. Leave enough collar on bag to permit folding collar over tying tape. (2) Place a minimum of 2 wraps of pressure-sensit've tape RB0195-002 (Rocketdyne) o1 (Federal Specification PPP-T-60) elther aver lying tape or down- stream adjacent to tying tape. (3) Fold bag collar over tying tape and pressure-sengitive tape; then, using pressure- sensitive tape RBO195-002 (Rocketdyne) or (Federal Specification PPP-T-60), tape bag collar securely, overJapping pressure-senaitive tape onto tube or fitting. R-3896-11 (4) Vent each bag by puncturing a 1/8-inch hole in top of bag in a location that will prevent entry of contaminants into bag. (5) A second bag may be installed over first bag, as outlined in substeps 1 through 4, if the vent hole in outer bag is diametrically opposite of vent hole in inner bag. e. On engines to be installed or on engines ingtalled in S-IC stage in positions 103 and 104, perform the following: (1) Remove attaching hardware that secures No. 1 fuel valve position transducer vent drain tube to fuel valve. Retain attaching hardware for reinstallation if acceptable for reuse in accordance with requirements of section II. (2) Remove No. 1 fuel valve position transducer vent drain tube from between fuel valve and tee, and drain residual fluid into a container. Measure and record volume of fluid collected. (3) Plug each end of No. 1 fuel valve position transducer vent drain tube; package tube as required to prevent contamination, tag tule package with part name, part number and serial number of engine from which tube was removed; and retain tube in storage for reinstallation. (4) Install clean bags made from plastic shect and strip (Federal Specification L-P-378, Type {1) (one gallon minimum volume) on open fitting on fuel valve and on tec as follows: (See figure 3-165. ) NOTE Clean polyethylene bags (Kederal Stock No. 8105-LCO-6811) 12 by 18 inches, or clean polyethylene tubing (Federal Stock No. &135-782-7460) 7-1/2 inches wide, cut to one-gallon minimum volume and heat sealed at one end, may be used instead of plastic sheet and strip. All poly~ ethylene material uged must be 0,004 inch thick. (a) Insert open end of bag over fitting or tee. Pleat bag around fitting or tee, and secure bag to fitting or tee with Airtex 217 tying tape, Type Ii (Eon Corp) or equivalent. Leave enough collar on bag to permit folding collar over tying tape. Section II (b) Pluce a minimum of 2 wraps of pressure-sensitive tape RBO195-002 (Rocketdyne) or (Federal Specification PPP-T-60) either over lying tape or downstream adjacent to tying tape. (c}) Fold bag collar over tying tape and pressure-sensitive tape; then,using pressure- sensitive tape RB0195-002 (Rocketdyne) or (Federal Specification PPP-T-60), tape bag callar securely overlapping pressure~-sensitive tape onto fitting or tee. (ad) Vent each bag by puncturing a 1/8- inch hole in top of bag in a location that will prevent entry of contaminants Into bag. (e) A second bag may be installed over first bag, as outlined in substeps a through d, if the vent hole in outer bag is diametrically opposite of vent hole in inner bag. f. On engrines to be installed or on engines installed in S~IC stage in positions 101, 102, and 105, perform the following: (1) Remove attaching hardware that secures No. 2 fuel valve position transducer vent drain tube to fuel valve and to No. 2 fuel valve open tube. Retain attaching hardware for reinstalla- tion if acceptable for reuse in accordaace with requirements of section I, (2) Remove No. 2 fuel valve position transducer vent drain tube from between fuel valve and tec, and drain residual fluid Inlo a container. Measure and record volume of fluid collected. (3) Plug each end of No, 2 fuel valve posi- tion transducer vent drain tube; package tube as required to prevent contamination; tag tube package with part name, part number, and serial number of engine from which tube was removed; and retain tube in storage for rein- stallation. (4) Install clean bags made from plastic sheet and strip (Federal Specification L-P-378, Type I) (one gallon minimum volume) on open fitting on fuel valve and on tee ag follows: (See figure 3-16R. ) Change No. 7 ~ 28 April 1970 3-192A Section III Paragraph 3.6.23, 2 NOTE Clean polyethylene bags (Federal Stock No, 8105-LCO-6811) 12 by 18 inches, or clean polyett ylene tubing (Federal Stock No. 8135-782-7460) 7-1/2 inches wide, cut to one-gallon minimum volume and heat sealed at one end, may be used instead of plastic sheet and strip. All poly- ethylene material used must be 0.004 inch thick. (a) Insert open end of bag over fitting or tee. Pleat bag around fitting or tee, and secure bag to fitting or tee with Airtex 217 tying tape, Type II (fon Corp or equivalent. Leave enough collar on bag to permit folding collar over tying tape. (b) Place a minimum of 2 wraps of presgure-senasitive tape RBO195-002 (Rocketdyne) or (Federal Specification PPP-T-60) either over tying tape or down- stream adjacent to tying tape. (c) Fold bag collar over tying tape and preasure-sonsitive tape; then, using pressure- sensitive tape R130195-002 (idocketdyne) or (Federal Specification PPP-I'-60), tape bag collar securely overlapping pressure-sensitive tape onto fitting or tee. (d) Vent each bag by puncturing a 1/8-inch hole in top of bag in a location that wil) prevent entry of contaminants Into bag. (e) A second bag nay be installed over first bag, ag outlined in substeps a through d, if the vent hole in outer Lag ig diametrically opposite of vent hole in jiner bag. g. Install cover on fel overboard drain line at thrust chamber exit. Tighten fasteners fingertight plug 1/4 tun. 3.6.23, 2 Detormini ag Inspection Intervals of Drain System fgolafion Baga. a. ‘Twenty~-fox hours after preparing system for isolation (pa 'agraph 3.6.23.4), inspect bags for fluid collection. If fiutd is evident, remove bags and measure total volume of fluid collected. Record fluid volume us Day 1 volume for a futuro calculation. If fluid is not evident, omit steps b through d. 3-132B Change No. 7 - 28 April 1970 R-3896-11 b. Install a clean bag made from plastic sheet and strip (Federal Specification L-P-378, Type II) (one gallon minimum volume) wherever a bag was removed as follows: (See figure 3-16B.) NOTE Clean polyethylene bags (Federal Stock No. 8105-LCO-6811) 12 by 18 inches, or clean polyethylene tubing (Federal Stock No, 9135-782--7460) 7~1/2 inches wide, cut to one-gallon minimum volume and heat sealed at one end, may be used instead of Plastic sheet and strip. All poly- ethylene material used must be 0.004 inch thick. (1) Insert open end of bag over tube or fitting. Pleat bag around tube or fitting, and secure bag to tube or fitting with Airtex 217 (ying tape, Type If (Fon Corp), or cquivalent. Leave cnough colar on bag to permit folding collar over tying tape. (2) Place a minimum of 2 wraps of pressure-senaitive tape R0195-002 (Rocketdyne) or (Federal Specification PPP-T-60) either over tying tape or downstream adjacent to tying tape. (3) Fold bag collar over tying tape and pressul e-sensgitive 4... then, using pressure~ sensitive tape RBO195-002 (Rocketdyne) or (Federal Spacifleation PPP-T-60) tape bap collar securely, overlapping pressure-sensitive tape onto tube or fitting. (4) Vent bag by puncturing a 1/8-inch hole in top of bag in a location that will prevent entry of contaminants into bag. (5) A second bag may be installed over first bag, as outlined in substeps 1 through 4, if the vent hole in outer bag is diametrically opposite of vent hole in inner bag. c, Twenty-four hours after reinstalling bags, again Inspect bags for fluid collection. If fluid is evident, remove bags and measure total volume of fluid collected. Record flufd volume as Day 2 volume. R-3896-11 cl. Determine subsequent inspection intervals (maximum intervals, 30 days) using the follew- ing formula: Day 1 vol (ec) + Day 2 vol (ce dx days)=3, 764 cr e. If fluid is not evident in bags or if inspce- tion intervals (when using formula) exceed 30 days, subsequent inspection must be performed at 30-day intervals and bags emptied ag re- quired, 3.6.23.3 Securing Drain System From Isolation. a. Remove cover from fuel overboard drain line at thrust chamber exit. b. Install o clean bag made from plastic sheet and strip (Federal Specification L-P-378, Type II) (one gallon minimum volume) on fuel overboard drain line at thrust chamber exit as follows: (See figure 3-16B. ) NOTE Clean polyethylene bags (Federal Stock No. 8105-LCO-f811) 12 by 18 inches, or clean polyethylene tubing (Federal Stock No. 8135-782-7460) 4-1/2 Inches wide, cut to one-gallon minimum volume and heat sealed at one end, may be used instead of plastic sheet and strip. All poly- ethylene material used must be 0.004 inch thick. (1) Insert open end of bag over tube. Pleat bag around tube, and secure bag to tube with Airtex 217 tying tape, Type lI (Eon Corp), or equivalent. Leave enough collar on bag to permit folding collar over tying tupe. (2) Place a minimum of 2 wraps of pressure~-sengitive tape RBO195-002 (Rocketdyne) or (Federal Specification PPP-T-60) cither over tying tape or down- stream adjacent to tying tape. (3) Fold bag collar over tying tape and pressure-sensitive tape; then,using pressure- sensitive tape HB0195-002 (Rocketdyne) or (Federal Specification PPP-T-60), tape bag collar securely, overlapping pressure - sensitive tape onto tube. (4) Vent bag by puncturing a 1/8-inch hole in top of bag in a location that will prevent entry of contaminants into bag. Section If Paragraph 3.6,23.3 A pe A ~ POLYE WIYLENE BAG Pe PUBE (TYPICAL) PRESSURE- SENSITIVE TAPE PRESSURE - SENSITIVE i tes Ex Figure 3-168. Drain System Isciation Bag Installation (Typleal) (5) A second bag may be installed over first bag, as outlined in substeps 1 through 4, if the vent hole in outer bag is diametrically opposite of vent hole in inner bag. c. Remove bags from crogs-to-lateral drain tube and from Y-fitting on fuel overboard drain line. d. Loosen crogs-to-lateral drain tube at cross. Rotate tube to aline with Y-fitling on fuel overboard drain Jine. Change No. 7 - 28 April 190 3-132C Section II Paragraphs 3. 6.24 to 3.6.24. 2 NOTI!s The method for applying lubricant in the following procedure is outlined in R-3896-3, e. Lubricate (Method A) fittings and (Method G) tube with lubricant grease RBO140-012 (Rocketdyne) and instal! cross-to-lateral drain lube. Torque tube coupling nuts to 1,200-1,400 in-1b, f, On engines installed in S-IC stage in posi- tions 103 and 104, remove bags from fitting in fuel valve and from tee; then install No. 1 fuel valve position transducer vent drain tube as follows: (1) Lubricate (Method A) fittings and (Method G) tube with lubricant grease RBO140-012 (Rocketdyne). (2) Install tune. Torque tube coupling nuts to 135-185 in-lb, (3) Install cla up between tube and fuel valve, ‘Torque attaching hardware for clamp to 8-10 in-lb, g. On engines fnstalled in 8-IC stage in posi- tions 101, 102, and 105, remove bags from fitting in fuel valve and from tee; then tnstal) No. 2 fuel valve position transducer vent drain tube as follows: (1) Lubricate (Method A) fittings and (Method G) tube with lubricant trrease RBO140-012 (Rocketdyne). (2) Install tube. Torque tube coupling nuts to 135-185 in-Jb. (4) Install clamp between tube and fuel valve and claraps between tuhe and No, 2 fuel valve open tube. Torque attaching hardware for clamps to 8-10 in-Jb. 3 6.24 PREPARING AN) SECURING OXI. DIZER AND NITROGEN OVERBOARD DRAIN LINES FOR ROTATING STAGE TO HORIZON TAL POSITION. 3.6.24... Propariny Oxidizer and Nitrogen Overboard Drain Lines for Rotating Stage to Horizontal Position. a. Remove pjate RX20636, if installed, from exit end of oxidizer overboard drain line, 3-132D Chanpe No, 8 - 9 September 1970 R-3896-11 b. Remove plug RN265-2001-0008, if installed,” ” 1 exit end of nitrogen oveeboar rain Hne. from exit end of nitrogen ovceboard drain i c. Install clean bags maae frorn plastic sheet and strip (Federal Specification L-P-378, Type II) (one-gallon minimum volume) on exit 2nds of oxidizer and nitrogen overboard drain lines as follows: NOTE Clean polyethylene bags (Federal Stock No. 8105-LC0-6611) 12 by 18 inv hes, or clean polyethylene tubing (Federal Stock No, 8135-782-7460) 7-1/2 inches wide, cut to one gallon minimum volume and heat scaled at one end, may be used instead of Mastic sheet and strip, All poly- ethylene material used must be 6,004-inch minimum thickness, (1) Insert open end of bag over line. Pleat bag around line, and secure bap to line with Airtex 217 tying tape, Type U (fon Corp), or equivalent. Leave enough collar on bag to per- mit folding collar over tying tape. (2) Place a minimum of 2 wraps of pre ssure- sensitive tape RBO195-002 (Rocketdyne) or (Federal Specification PPP-7-60) over tying tape or downstream adja tent to tying tape. (3) Fold bag collar over tying tine and pressure-sensilive lape; thon, using pressure- sensitive lape RBO195-002 (Rocketdyne) or (Federal Specification PPP-T-60), lape bag collat securely, overlapping pressure-sensitive tape onto line. (4) Vent each bag by puncturing a 1/4-inch hole in top of bag in a location on the low side of the line when the stage is rotated to the hori- zontal position, d. Turn on turbopump LOX seal purge and verily bag installation before installing stage engine covers, 3.6.24.2 Securing Oxidizer and Nitrogen Overboard Drain Lines, a. Remove bags from oxidizer overbuard drain line and install plate RX20636 on line. Tighten fasteners fingertight plus 1/4 turn. b, Remove bags from nitrogen overboard drain line and install plug RD265-2001-0008 on line. Tighten plug fingertight, R-3896-11 3.7 MAINTAINING ENGINE LOG BOOK, 3.7.1 PURPOSE, ‘The following paragraphs contain the general requirements and Instruc- tions necessary to produce entriear of standard accuracy and completeness with log book de- Jivered with the engine, “he Engine Log Book is the official document for recording the operational status and configuration of the engine from production to launch. 3.7.2 SOURCE DOCUMENTATION. In order to assist in the maintenance of the Engine Log Books, the entries required for a task are specified in engine Modification Instructions, Engine Field Inspection Requests (EFIRs), and Field Task and Verification Plans (FTVPs) that support technical manual instructions, Modification Instructions and EFIRs incorpo- rate necessary instructional steps and an attachment for ley book data transmittal to organizations having log book maintenance re- sponsibility. FIVPs specify log book entry FT VPs to be used for Jog book data transmittal to organizations having log book maintenance responsibility. 3.7.3 WHEN TO UPDATE LOG BOOK, Log books must reflect open as well as completed tasks or events, and initlal entries should be made as soon as requirements aye identLfied or approval documents received. The log hook must be updated at least each time any of the following tasks or events are completed: (Rocketdyne Configuration Report R-6857 may be used to verify open log book entries for modification and Engine Field inspection Request {E FIR) tasks. ) a. Engine Contractor receiving inspection b, Stage Contractor receiving inspection c. Engine post-modification checkout d. Storage e. Preparation for shipment f. Pre-static firing modification and checkout g. Prelaunch Section IT Paragraphs 3.7 to 3.7.4.5 3.7.4 HOW TO UPDATE LOG BOOK, Log book entries should be typewritten. Entries handprinted in ink are acceptable when type- written entries are impractical, (Additional eoneral rules are outlined in paragraphs 3.7.4.1 wad 3.7, 4,10.) d.%.4.1 Abbreviations. Abbreviations to be used in the preparation and maintenance of the Engine Log Book are listed in the introductory data of the individual log books or are defined in this manual. The abbreviations UNK or DNA must be inserted in blank spaces for which in- formation is unknown or does not apply. 3.7.4.2 Definition of Terms, The terins to be used in preparation and maintenance of the Engine Log Book are listed in the introductory data of the individual log books or are defined in the detailed instructions in this manual. 3.7.4.3 Identifying Vehicle, Organization, and Location,” The symbols used in preparation and maintenance of the Engine Log Book, to identify the vehicle, sites (locations), and organizations must be consistent with the follow- iag: a. Vehicle: Saturn V, first stage, S-IC-X Lb, Organization locations: (1) Rocketdyne, Michoud Assembly Facility, RD-MAF (2) Rocketdyne, Kennedy Space Center, RD-KSC (3) Rocketdyne, Marshall Space Flight Center, RD-MSFC (4) Rocketdyne, Mississippi Test Facility, RD-MTF to the desired number of significant figures by rounding up whenever the digit next to the last desired significant figure is 5 or greater and counding down whenever the digit next co the last desired elgnificant figure 1s less than 5. Change No. 4- 6 August 1969 3-133 Section M Paragraphs 3.7.4.6 to 3.7.6 3.7.4.6 Verifying Log Book Entries (Log Book Audit), Engine Log Books must be reviewed at Teast concurrent with each recelving inspection and prior to shipping and launch, to assure that the books are complete and accurate. Log book audits will be documented on the Transfer Record of the log book. Government inspection signoff is required for these entries. (Rocket- dyne Configuration Report R-5857, may be used to verify open log book entries for modification and Engine Field Inspection Request (EFIR) R-3896-11 NOTE Government inspection signoff of entries on specified forms is not re> quired except when a log book audit is performed. 3.7.5 TRANSFERRING LOG BOOK, The Engine Log Book must accompany the engine whenever custody is transferred or the engine is shipped. The organization having custody tasks, ) >, of the engine is responsible for transferring ‘< theslog book. 3.7.4.7 Deleting Log Book Entries Made in <2f{v \* Error. Erasures are not permitted. Jf an ae LOG BOOK FORMS THAT REQUIRE error 1s made,the incorrect entry must be Or ROG? DELIVERY MAINTENANCE, The Engine voided and the abbreviation EIE (entered in “a Log Book consists of 11 major sections contain- error, entered adjacent tu the line. The initials or stamp of the individual who made the entry must be entered adjacent to the entry. 3.7.4.8 Indicating Obsolete Log Book Entvies. Erasures are not permitted. With a single inked line. Hae out the obsolete entry, thus indicating that the entry no longer reflects the current engine configuration. Do not obliter- ate the entry. The initials or stamp of the individual voiding the entry must be entered adjacent to the Ine, 3.7.4.9 Inserting Additional or New Log Book Forms, Addilional copies of the same torm must be utilized in the event a single form does not provide sufficient space for recording all of the required information. These forms must he added ta the log book immediately behind the form affected. All new or additional forms must have the engine model and serial number entered on the form prior to insertion in the log book. All new or additional, log ook forms must be dated and numbered consecu- tively in accordance with the existing page numbering system, 3,7.4.10 Entering Inspection Signatures or Stamps. é individual making a data cntry Inthe Engine Log Book must also enter nis signature or stamp in the inspection signoff column of the log book form. Unless otherwise specified in the detalled instructions, the sig- nature or stamp is a verification of the accuracy and completeness of the entry as transcribed from the source data and does not indicate verification of the completion or observance of a specific task. 3-134 Change No. 4 - 6 August 1969 “ing engine records and farms. Instructions for completing log book form entries, corrections, and transfers are presented for those forms that may require post-delivery maintenanc>: these forms are: Component Data section Primary Flight Instrumentation System Road Map Component Records section Component Test Record Engine Data section Post-Delvery Performance Uncertainty Record(a) Engine Weight Record Engine Records section Engine Test Record Configuration Record section Configuration Record ered but must be inserted subsequent to engine delivery. R-3896-11 Serialized Component Record sectlon Nelivered Serialized Component Record Rigid-Duct Spacer Dimensions!) Post-Delivery Serialized Component Replacement Record Post-Delivery Flight Instrunientation Pressure Transducer Replacement Record(@) Orifice Record section Delivered Orifice Record Post-Delivery Orifice Replacement Record Operational Data Log section ) é ; . a Post-Delivery Component Cycle Record Cperational Data (Heat Exchanger Pe1form~ ance Summary) Maintenance Record section Discrepany Record Inspection Record Turbopump Preservation Record Age Control Log For Component Syuchetic Rubber Items fe Loose ktuipnent Fiight Installation Record’* Transfer Record Section Transfer Record p= ae tie er eth ail (a) ‘This form is not in all log books as deliv- ered put muat be ingerted subsequent to engine delivery. (b) This forra may be found in either of two configurations in the log book. Instructions are provided for the maintenance of both forms. Section If Paragraph 3.7.7 3.7.7 HOW TO DETERMINE LOG BOOK ENTRY REQUIREMENTS, The Minimum Log Pook Entry Requirements chart (figure 3-17) identi- fies which log book fo +1 must be updated when specific tasks are performed or events occur. Figure 3-J7 reflects minimum require- ments; additional Jog book forms {net Listed in figure 3-17) may be affected depending on the nature or results of the task or event. Figures 3-18 through 3-37 specify when er under what conditions the additional forms will be affected. To determine the necessary log book entries for a specific task or event, proceed as follows: (See figure 3-17.) a. Select the title that best describes the task or event. Example: An engine modifica- tion is to be performed in accordance with an approved Rocketdyne Engineering Change Pro- posal (ECP); the task title in figure 3-17 is Modification, b, Search across the page to lozate the figure number of the applicable instructions. This figure 3-23 provides general and detailed in- structions for completing the log book form and makes reference to other log book formes that are (or may be) affected, depending on the nature and results of the task or event. The 4's indicate the other forms that must be up- datud for that specific task or event. Change No. 7 ~ 28 Aprt] 197u 3-135 Section IT] R-3896-11 Dard 4 | Log Book Form a 8 FA a] 2 a Fs 7 3 a b B He es a 0 a Q as a ok g | ge] 6 ¢ | 8 (8 {88 | & ra s a fa &) Fa fe ° 61 ee] ep |e [* [Bey 8 % Ba: 9 g = 3 i w a ye 5 a & a? Ee Fr ty fe S BS ay In G @ 2) &) fe | £ | & | BE led | 4 .) + Bo g 2 |re | os & a } ES Be on) aod | 6% be Task or Event fx O YES) ‘a & ae (94 i Shipping 3-37 Receiving 3-37 iInspections Log book audit 3-37 Turbopump prescrvation 3-34 Static firing 3-22 Modification Discrepancy disposition (UCR) Component cycling 3-31 | Loose-equipment flight 3-36 installation Launch x 3-37 NOTE The figure numbers and X's repre- sent the minimum log book forms affected by a specific task or event, SR ES as A EN Figure 3-17. Minimum Log Bouk Entry Requirements 3-136 Change No. 4 - 6 August 1968 696] WNFy g - Y "ON aBuTY:) LEE-E F-! PRIMARY INSTRUMENTATION SYSTEM ROAD MAP ENGINE SERML NO FAK SER Mast COTE — PARAKETER rts MANS car REOUEED GM BRATION D HP ALE TE RANE SPECISICATION me aU SONI Ria CEST eee ee octal a Be Be TO VEL TROP ZT WO 28 j Oo TO OO Fuh | Mad- 2744072 STATHAM PRES Ute 1 qa tet Pte Dears he Hh La hy YMEKTs OF Late } TURE OUTLET Pal | 0 70 100 PSA | NAD-27e80TIF stan Va Ot tous ua Lid Wis NONI CUDA Juispwut Ol fn 12baaOke ot COMMON YDA ay RET YN 98 2 TO SOC PS | NAS-7/8807S ATATHAN Phatexm | wh aT AD Par, | Pompano) + O1MOnTR a | GHIGGZEX TUROOPAE BERATED JET PR © 70 000 MEA | MASRTERGTO | ac iM LEY | 2 TO 2n00F WAS TraTZ arash Mo PL OTLEND 00 | ESD SI, De 7. LOT tA Bel eet SLITS Tree SALE, Ma MANUFAC TURE rm ATION || ae | PARAMETER STROKE SPECIFICATION et a os Set ur Mae NOY POTIT OR POTENTHOMETEN TOW? £ 0.060 wal WAS-E7EOe THUD Peers) “Ure | ab wy MD 2 POSITION SOTENTOMETES Rots OCeaw { me$- 27408 filra se Apendd = LaPHE Te + aa we WO 1 POSITION POTES THOMETER 2342 0 O30 MAS 27338 Tithe rama ES iw an MOY MS 2 POUTION PITENTIONE TTA T34G 20 O301M) MES~ 27IIG THD vate OTE ha nS GAS GENERATOR “QUVE SWITEHES HAS- 27443 HOVHNS EMA | “9 TURP Py rowel) | i LON SPEC RO NAS-27 UTICN PART NO Tare Sots nas arse are we sets PART to ow 19 NT Figat a Fea | wtaT Orcraneds Oa INET FLOWmaTE (TR joint ise nen OE: I. GENERAL INSTRUCTIONS, Zatries must be made in the Primary Instrumentation System Road Maps whenever a transducer is replaced, installed, or removed. Existing cntries for replaced or deleted transducers are lined out. Tf] DETAILED INSTRUCTIONS. Compiete form as follows: if a transducer is replaced or added to the engine, enter all data for transducer being installed. Obtain data from Individual Transducer Data Sheet shipped with new or | replacement transducer. NOTE Individual Transducer Data Sheets, manufacturer’s test and zalibration s heets, IBM printouts, and IBM cards are not inciuded in the log ‘book out are re- tained as part of the log book backup date. Line out when applicable, all dati for transducer being removed. (Refer to paragraph 3.7.4.8.) Individual Transducer Data Sheet, manufacturer's test and calibra- tion sheets, IBM printouts, and IBM cards for the re- moved transducer must be removed from log book back- up data and routed with the removed transducer. Enter stamp or signature of individual who ned out entries. Enter stamp or signature of individual making ertries from individual Transducer Data Sheet. Figure 3-18. Primary Instrumentation System Road Map Ii -S68e-uU I woyyo0g Section I i, GENERAL INSTRUCTIONS, The Component Test Record (CTR) of each of the vomponents listed in paragraph II, contain- ing the results of the required functional tests, must be included in the log book. No entries are required on the CTR as a function of log book maintenance. The forms arc removed from or jnserted in the log hook whenever their respective component is removed from or installed on an engine. ll, DETAILED INSTRUCTIONS, Whenever one of the following components is replaced, remove CTR of removed component from log book and insert CTR for installed component in its place: NOTE Some components that do not appear on this list will be accnmpanied by CTRs. When these cornponents are replaced, the CTR for the installed component should be retained with the engine maintenance records. e The removed CTR trust accompany the removed component. a. Turbopump assembly b. ‘Furbopump heater thermostat ce. Turbopump tachometer d. Turbopump bearing coolant valve assembly e. Gas generator ball valve assembly Gas generator ball valve switch 3-138 Change No. 4 - 6 August 1869 LE A a PI Figure 3-19. Component Test Record R-3896-11 g Hydraulic manifold assembly h. Hydraulic control 4-way valve assembly i. Hydraulic control valve stop solenoid valve assembly j. Hydraulic contro} valve start solencid valve asserably Hypergoi manifold assernbly Ignition monitor valve assembly Main LOX valve assembly k ] m. Hypergol installed switch n o. Main LOX valve indicator assembly D Main fuel valve assembly 4. Main fuel valve indicator assembly Checkout valve assembly r sg. Checkout vaive assembiy rotary actuator t. Thrust chamber inert prefill check valve u . Heat exchanger LOX supply assembly check valve v. Heat exchanger LOX supply check valve w. GX dome purge check valve x. Gas generator LOX purge check valve y. Pressure-sctuated calibratable-type switeh R-3896-11 a ar AES vive oe Paki “PERSE ROOK Feb DELIVERED PERFORMANCE UNCERTAINTY Replaced gas generator injectors New BAN SOULNG-EL, S/N O749 FUG Replaced Cownaliroam gna gensintor TO ataifice. New PAN W251 11 0~00K6 Rerababratinon to F925 HIP thrust, differenecs an as generator injector pressure drop means, anid resulting orifice pressure drop excvreian. 1964 IW A, 1, GENERAL INSTRUCTIONS, Entries must be made In the Post-Delivery Performance Uncertainty Record whenever performance uncertainty is increased as a result of specified components being replaced, or reeyaluated as a result of subsequent testing or data analysis. Refer to section Il fora cormplete list of components that require entries if replaced, Il, DETAILED INSTRUCTIONS, Compiete form as follows: ENTRY DATE - Enter date entiyis made. SOURCE OF PERFORMANCE UNCER- TAINTY ~ If performance uncertainty is to be increased ag a result of cornponent replacement, enter name, part number, and serial number of component belng replaced, For reevaluated uncertainty, enter reason for reevaluation, such as identification of subsequent testing, or name, date, and number of document that provided new values for maximurn expected performance uncertainty, Figure 3-20. Post-Delivery Performance Uncertainty Record POST DELIVERY PERFORMANCE UNCERTAINTY RECORO HOMIMUM EXPECTED PERFORMANCE UXCERTAINTIES SEA LEVEL THRUST we O.000 Section TI LE SS AT i TS ENGINE S/N P=2OXX_ — | mnmmnamement CUMULATIVE 4AXIMUN EXPECTED PERFORMANCE UNCEATAINTY SEA LEVEL MIXTURE RATIO SEA LEVEL THRUST MIXTURE AATIG 0.01! UPR La) 0,00] 1.0 TF O01. 002 DATE MAXIMUM EXPECTED PERFORMANCE UN JERTAINTIES - Enter numerical values of maximum expected performance urcertainty for listed source of perform- al.ce uncertainty. Refer to section U for numerical values resulting from replace- mnt of specified components. Numerical vélues resuiting from subsequent testing must be extracted from documentation approved by Rocketdyne Engineering. SAVR Wop e CUMULATIVE MAXIMUM EXPECTED PEY FORMANCE UNCERTAINTY - For increesed performance uncertainty due to component replacement, enter root sum square of previous cumulative maximum expected performance uncertainty and un- certainties resulting from component re- placement. For reevaluated uncertainty, enter same numerical values that were entered in Maximum Expected Perform- ance (Jncertainties column. Refer to section Il for calculation procedures and methods of handling second and subsequent replacements of a particular component, 3-139 Change No. 4 = 6 August 1969 Section Mil R-3896-11 ENGINE WEIGHT RECORD chines aya B2OKe DATE OF ORIGINAL weiowna AML GT weioHe pen spec RA0220-652 | spec went, onv 1 “ - POUNDS} i pt B ttc ih: wry : $ Gp ner weiont, EBuer anw® Giwer wonenr Wap mance rion Pory(PouNos) | tINCHES) TROUNDS-INCHESIT rer erom| “ae NT | 17,416 54.6 17,628 | 17,630 DNA 17,648 DNA 17, 649.5 __DNA Lat a Pear a tm ein ATTEN Wo ehe Le PoMeeRO OF pate JK APR OP | I. GENERAL INSTRUCTIONS, Qo MD MOMENT CHANGE (POUNDS- INCHES) ~ Enter moment change resulting from modification. Indicate if moment change is plug (+) or minus (-). leiteies must be made in the Engine Weight Record whenever engine weight is affected by an engine modification resulting from an ap- proved Engineering Change Proposal (ECP), @ NET WEIGHT, DRY (POUNDS) - Add or . ; subtract, as applicable, value ontered in Ii, DETAILED INSTRUCTIONS. MD Weight Change (Pounds) cui iran for Complete forin as follows: this modification to last listed .alue in NOTE this column. Obtain entry information for columns @ NET MOMENT (POUNDS-INCHES) - Add 1 through 5 from Modification Instruc- or subtract, as applicable, value entered tion R-5266-XXX, : in MD Moment Change (Pounds-Inches) column for modifleation to last listed @ DESIGN CHANGE NO. (ECP) - Enter value in this columu. design change number (ECP) number. NET ARM (INCHES) - Divide value @ MD CONFIGURATION NO. - Enter entered in Net Moment (Pounds-Inches) modification designation (MD) number, column by value entered in Net Weight, if applicable, Dry (Pounds) column and enter result here. @ MD WEIGHT CHANGE (POUNDS) - Enter weight change resulting from modifica- & INSPECTION - Enter stamp or signature tion. Indicate if weight is added (+) or of Contractor representative making subtracted (-). entries, Finter DNA in Government colunm. @ MD ARM (INCHES) ~- Enter horizontal arm length of modification. Indicate if arm length is measured in aft (+) direc- tion from gimbal bearing centerline or in forward (-) direction from gimbal! bear- ing centerline, —— a Sas | Figure 3-21. Engine Weight Record 3-140 Change No. 4 - 8 August 1969 R- 3896-11 A!.EO ALED CURATION | STARTS 419,69 I, GENERAL INSTRUCTIONS, Entries must be made in the Engine Test Record to record infurmation concerning engine tests conducted after delivery. If, DETAILED INSTRUCTIONS. Complete form as follows: TEST NUMBER - Enter letters and/or numerals that designate testing facility and/or vehicle identification, and enter test sequence number. 2] TEST DATE - Enter date test is conducted, & TEST DURATION - Enter effective dura- tion (Thrust OK Pickup to Stop Solenoid Signal) of test to nearest 0.1 second. TOTALED DURATIUN ~ Enter accumu- lated effective duration of a1] testa of engine to nearest 0.1 second. eres: Figure 3-22, Objectivea: Reeulta: Section I ENGINE $/M—L-20XX_ TEST COMMENTS S-TC-8 atnge firing to verify engine performance, Satisfactory. —— ere 1h APR 67 & TOTALED STARTS - Enter accumulated starts of engine. @ TEST COMMENTS - Enter pertinent com- ments concerning engine performance, malfunctions or part failures, and effect on (or of) facility or vehicle systems significant for evaluation of overall engine performance. WI. OTHER LOG BOOK FORMS THAT ARS (OR MA MAY BE BE) A AFFECTED, A. POST-DELIVERY PERFORMANCE UN- C CERTAINTY "RECORD. Reevaluate engine performance uncertainty and make necessary Post-Delivery Performance Unce1tainty Record changes resulting from post-delivery engine testing. (See tigure 3-29 for instructions. ) Engine Test Record Change No. 11 - & May 197) 3-141 Section tI R-3898-11 OP Ri - A CONFIGURATION RECORD tee . re neehey pono | ee ORGANIZATION —wv FA te re ee Replacemece¢ of emine en froumental temp transducer, DMAP (326006900, 17 Jan 6a Ioplecenent of heat oxehanger avadom ofifices, 1d Sep fe RD AL Path -jut, 2 Feb os F'=340 Tncorporatinn of improved soppord brackets Pot Ihosep te ROAR hvdvadlhie qauftod Toes, Heoehe350, .! Fob os PY --F47 Toapection and reiteutalication of thrust Oh nope Ok ttlt-S1 Ub poessure switches, Wee Gs7, EL apr 64 Flee 72 Replacement ad theust chacer diate plage, ns (Wee Ap HeFlOt— bot, PL Mas G8 Fl-3e1 Replacemest of ces cugioratar boll vatyve bushing, IN ful fx AIPMAF I. GENERAL INSTRUCTIONS, The Configuration Record is used to record Ae design changes incorporated on the engine sub- sequent to engine delivery. Entries are initially made on this form upon receipt of an approved modification and again at completion of the In- stallation. The entries pertinent to completion af the installation are not dependent upon com- pletion of post-installation checkout. The record also reflects the current composite MD number at the time of shipment or launch. Ra FLOL Rae, 4 May racy to Shapment: | Ik, DETAILED INSTRUCTIONS. Complete form as follows: A. Upon receipt of an approved Madification Instruction, complete columns 1, 2, and 3 as follows: DESIGN CHANGE NO. ~- Enter design change (ECP) number including revision 3 (Ri, R2, etc), if applicable. DESCRIPTION OF CHANGE - Enter Modification Instruction title, number, and date as obtained from Modification Instruction. DATE NOV L067 ¢ MD NO, - Enter modification designation (MD) number as obtained from Modifica- tion Instruction. NOTE ff the modification requirement is canceled prior to completion of the installation, the initial entries (columns 1, 2, and 3 must be lined out). (Refer to paragraph 3.7.4.8, B. Upon completion of modification installaticn, complete columns 4 and 5 as follows: a COMPLETION DATE - Enter date modifi- caticn installation is completed, ORGANIZATION - Enter orgs ization identification and location where modifica- tion installation is completed, Fnier stamp or signature of individual making entry. C. Prior to engine shipment or launch, complete form as folluws: @B vescripTion OF CHANGE - Enter words "Prior to Shipment” or “Prior to Launch,” as applicable, and current composite MD number. The MD number must reflect all completed ECPs. Figure 5-23. Configu. ation Record (Sheet 1 of 2) 3-142 Change No, 4 - 6 August 1969 R-3896-11 er ill, OTHER LOG BOOK FORMS THAT ARE (OR MAY BE) AFFECTED, A. COMPONENT TEST RECORD, If madifi- cation required addition, deletion, or replace- ment of a component that has a Component Test Record (CTR), make necessary changes to forms involved. (See figure 3-19 for instruc- tions, ) B. POST-DELIVERY PERFORMANCE UN- CEPTAINTY RECORD. If engine performance uncertainty i is affected hy modification, make necessary Post-Delivery Performance Uncer- tainty Record changes. (See figure 3-20 for instructions. ) C. ENGINE WEIGHT RECORD, Uf modifica- tion creates an engine weight change, make proper entries in Engine Weight Record. (See figure 3-21 for instructions. } Section III D. RIGID-DUCT SPACER DIMENSIONS. i modification involved removal of componéi.ts that require accomplishment of fit-che-k pro- eedures, make changes on appropriate Tugid- Duct Spacer Dimensions form. (See figure 3-25 or 3-26 for inytructions. ) POST-DELIVERY SERIALIZE COMPO-~ en T REPLACEMENT RECCRD, lf modifica- tion required a serialized compo'ient addition, replacement, or part nuronber clange, make proper entries in Post-Delivery Serialized Component Replacement Record. (See figure 3-27 for instructions. ) F. POST-DELIVERY ORIFICE REPLACE -~ MENT RECORD. If modification required an orifice replacement, make proper entries in Post-Delivery Orifice Replacement Record. (See figure 3-30 for instructions. } ee A A OS Se eYtaine Aientasi ne Figure 3-23, Configuration Record (Sheet 2 of 2) i. GENERAL INSTRUCTIONS. The Delivered Serialized Component Record lists, by itern number, certain engine serial- ized components that are Installed on the engine at the time of delivery. The only post-delivery alveration required on this form is the Hnihg out af entries when post-delivery replacement or reidentification of a listed serializea com- ponent {s performed. Il, DETAILED INSTRUCTIONS, Identify component that was replaced or re- identified, and correctly line out all obsolete entries for this component. (Refer to para-~ graph 3.7.4.8.) NOTE Loose equipment items listed on this fori are installed on the engine sub- sequent to delivery. Installation of this equipment is entered in the Locse-Equipment Fligh: Installation Record, (See figure 3-06.) ‘The In- spection coluinn of the Delivered Serialized Componert Record form should be completed with the stamp or sigitucure of the individual making entries, in ihe Loose-Equipment Flight Installation Record, when louse equipment is installed. Figure 3-24. Delivered Serialized Component Record Change No. 4 ~ 6 August 169 31493 Section Ill R-3896-11 re RIGID oa SPACER DIMENSIONS es -_ 1 DENTIFICATION OF SPACER TO aspran = SPACER OP se cer A1a1D OUCY SPACER ON OUTSIDE CIAMETER AN SIOWN oRLOW PMEAIGM Nhe wm {| "O'8 0.002 IH SPACER LOCATION TION Pen ely MU WO. | LOM VALVE PAK 406805 (liv) = 8/N WO.) LOX TP YOWTE PYM 408605 (117) S/N WO. 2 LOK VALVE oa P/N 408804 iv} on ee 2 Lox TF vOLUTE P/N 408803 (zr) 3/4 pee eee NG. 1 FUEL VALVE PAN 408606 (IFV) 3/N 0206964 0.878 6,863 MO. ! FUEL TP VOLUTE | P/N 408825 {1 FP) S/N 02650C8 2.571 2.570 i 126" 00' 009° 90° 1 WO 2 FUEL, VALVE ~ C/N 408608 (2F¥) S/N 7 a | | DRA NO. 2 FUEL TP VOLUTE P/M acea25 (2FP) S/N os = NOTE | SPACER IDENTIFICATION SH&L BE ABBREVIATED AS SHOWN WHERE L,F,¥ ANO F STAND aii fae TUEL, VALVE ANO PUMP RESPECTIVELY, caret ene eee FULL EPACERS AT THE TP FUEL VOLUTES THE OAIVE SCREWS SHALL SE * Roaitigte® COUNTER -CLCGF WISE FROM THE FORWARD MOUT Se RTRITIC ma THE TP FUEL VOLUTE WHEN FACING THE VOLUTE TO ALLOW FOR TRE SPACER ECCENTRICIT 3 ANGLE "C HAL BE OIVEM IM DEGREES COUNTER - CLOCKWISE FROM THE DRIVE aes To BPACER HIGH POINT WHEN FACING TP VOLUTE OR VALYE FLANCE LOx COME ER HO. INJECTION SER NO, rymican sevens “*|® * NOTE: THE EXPANCO TOOL SHILL BE LOCATED APPROX 90" AMAAT IN OF HEAR LOM DOME BOLT HOLES wo. 8 a St. me 6 . DATE ._Lb_ARB..A7__ I. GENERAL INSTRUCTIONS. SPACER LOW POINT "'B" +0. 002 IN, - Entries must be made on the Rigid-Duct Spacer Enter spacer low-point dimension re- corded during fit-check procedure. Dimensions (engines not incorporating MD137 change) form when the engine components that @ ANGLE "C" DEGREES - Enter angle "C" require the accomplishment of fit- check pro~ degrees recorded during fit-check pro- eedures are removed and reinstalled or re- cedure. moved and replaced. If no space is available ANGLE "D'' DEGREES - For applicable for entries on the form included in the log book spacers, enter angle ‘'D" degrees re- as delivered, a new (blank) Rigid-Duct Spacer corded during fit~check procedure. Dimensions form must be inserted when it is EXPANDO TOOL INSTALLATION REC- necessary to make entries subsequent to engine ORD - Information entered in this block is delivery. The original form must be retained for reference purposes when the oxidizer in the log book. dome and/or injector are removed from Il. DETAILED INSTRUCTIONS. the thrust chamber. Entries are not ap- Complete form as follows: plicable to rigid-duct spacer dimension IDENTIFICATION OF SPACER TO AP- requirements. j PEAR ON OUTSIDE DIAMETER AS NOTE SHOWN BELOW - Enter serial number of Entries on the existing log book Rigid- spacer on appropriate line (as indicated ayes Fea Go ientitaton the apnieale: in Rigid-Duct Spacer Location column). line for the affected spacer and cor- SPACER HIGH POINT "A" 20.002 IN, - rectly voiding obsolete entries. (Refer Enter spacer high-pcint dimension re- to paragraph 3.7.4.8. corded during fit-check procedure. cheba het met irmail iae RNLE S RN SOAS | — Figure 3-25. Fugid-Duct Spacer Dimensions (Engines Not Incorporating MDi37 Change) 3-144 Change No. 4 - 6 August 1969 R-3896-11 Section III RIGID DUCT SPACER DIMENSIONS OEGREES sevective GR Im) 2 SPACER b/W 7, SPACER SEE MOTE 1) 410637 ~ (96) ____ ENGINE 8/m ___Fo20XX RIGID DUCT SPACER LOCATION EXPANDO TOOL INSTALLATION RECORD OXID DC > SERIAL NUMBEK INJECTOR SEKIAL NUMBER ett oe cms @'Caa7~ CR) #10837 = C4) THRUST CHAMBER SERIAL NUMBLI: "0X10 DOME BOLT HOLE LOSATION NO, 4108 AT - (4) *OXID DOME BOLT HOLE LOCATION KO. ~ “| snot: THE EXPANOU TOOL SHALL BE LOOATED APPROXIMATELY 90 DEGREES APART IN OR NEAR OXID DOME BOLT HOLES NO. & AND 61 NOTES: 1, WHEN INSTALLING THE FUEL SPACENS AT THE TP FUEL VOLUTES, THE NOTCH SHALL BE POSITIONED "D" DIRIREKS COUNTER-CLOCKWISE FROM TH, FORWARD MOST POSITION OF THE TP FUEL VOLUTE WHEN PACING THE VOLUTE. 2 WHEN INSTALLING THE OID SPACERS AT THE TP VOLUTES OR VALVES, TYE NOTCH ON THE SPAGERS SHALL BE 410GMs ~ (41 41086 - 1%) NO. 2 FUEL TP VOLUTE | 410835 -(#) ae I aS POSITIONED "EX DEGREES COUNTER-CLOCKWISE FROM THE FORWARD MOST POSITION OF THE TP VOLUTE Of VALVE WHEN FACING THE VOLUTE OR VALVE FLANGES, 3. WHEN INSTALLING THE FUEL SPACER AT THE VALVE FLANGE, THE NOTCH SHALL BE POSITIONED "E" DEGREES COUNTER-CLOCKWISE FROM THE INBOARD MOST POSITION OF THE VALVE FLANGE WHEN PACING THE VALVE FLANGE. VIG ae : oaTe 39 AUG 68 I. GENERAL INSTRUCTIONS, © ANGLE "E" DEGREES - For applicable Te ee gm ae ’ * rene PA Entries must be rnade on the Rigid-Duct Spacer Sade eee ba a does = ; Dimensions (Engines Incorporating MN137 eg ee ae Een ees Berean: Change) form when the engine components that @ ' Pe c require the accomplishment of fit-check pro- EXPANDO d OOL INSTALLATION = : cedures are removed and reinstalled or re- ORD - Information entered in this block - moved and repl.ced If no space is avatlable for reference purposes when the oxidizer for entries on the ferm included in the log book ae ae Clie aie nemoved sal as delivered, a new (blank) Rigid-Duct Spacer +o Bint : aa itn i Stes ae ee es Dimensions form ‘ust be inserted when it is Pilcable to rigid-duct spacer dimension necessary to make entries subsequent to engine requirements. delivery. The original form must be retained in the tog book. Log books delivered with en- NOTE ines incerporating MD137 change may ecntain ok i Rigid-Duet Sineee Birsensione form that dif. Entries on the existing log book Rigid- fers from that shown. ‘fhe form shown should be ieee deaiviae ceste r it FS + : 9 7 \ ° be used when additional forms are needed cable line for the affected spacer and Il, DETAILED INSTRUCTIONS, correctly voiding obsolete entries, Complete form ag follows: (Refer to paragraph 3.7.4.8.) SPACER SELECTED - Enter dash number of spacer part number selected during fit-check procedure. & ANGLE "D" DEGREES - For applicable spacers, enter angle "D" degrees re- corded during fit-check procedure. roa — a ie ee an Et re Figure 3-26. Rigid-Duct Spacer Dimensions (Engines Incorporating MD137 Change) Change No, 4 ~ 6 August 1969 3-145 c Section TH __ Pal ONG 7% SUOTh9—1) fas penerator riajyectar Presyure shite Sn. | NAGH=URIRG=1 SOR50] Npeamure awitel Se, 2 NATHURING~ 1 SOM IO] Pressure aetteh Now 3 SVI-DS]H5-] 50459] NAG 27 Ne] NAGH272T TP H=] Inpine cnvitonmentatl temp transducer Main oxidizer valve No, DPhOUYGS AMS WWOhGFo] ney ee Mr O2 I. GENERAL INSTRUCTIONS, Entries must be taade in the Post-Delivery Serialized Component Record whenever the part number or serial number of setected serialized components changes as a result of component replacement or reidentification. Entries must be made for all replaced or re- identified components listed in Field Task and Verification Plan R-7241. Entries for replaced (or reidentified) serialized subassemblies, or details contained within an assembly that are nol listed in this document, are not necessary when the higher assembly is replaced (or reidentified). Il. DETAILED INSTRUCTIONS. Complete form as follows: NOTE If a component listed on this form is subsequently replaced or reiden- tified, line out the obsolete entries as outlined in paragraph 3.7.4.8. @ ITEM NO. ~ Enter card identification number from Field Task and Verification Plan that correaponds to component being replaced or reidentified. PART NAME ~ Enter name of component being replaced or reidentified. Figure 3-27, 3-146 Change No. 11-0 May 1971 POST DELIVERY SERIALIZED COMPONENT REPLACEMENT RECORD ORIGINAL SERTAL NO. ARN TH0G66 ec A RN RD 8 PN SS SANE SS ED Post-Delivery Serialized Component Replacement Record (Sheet 1 of 2) R- 3896-11 tyoiee gm FH2O0XX COMMERTS Inetadled per FCP PF) -996 OThOT IT PN change only per BP PL=547 No chruige MN change only per beP Pleoht Na ¢ hangre POS change only per FER Pi~Fh? Nc change 14737 Installed per IGP 11-306 YN change outy per HP RI-350 Na change PART NO. - Enter part number of compo- nent being replaced or reidentified. If NA5 component, make sure dash number suffix is included, if applicable. Jf part number of new component differs from part number of original component, enter new part mimber, then enter original part number, and enter reason for part number differ- ence in Comments column. @D cricinar SERIAL NO. - Enter serial number of component being replaced: if this column is not on form, use Comments column and indicate "ORIG S/N." & NEW SERIAJ, NO. (or SERIAL NO. ) - Enter serial number of component being installed. ® COMMENTS - Enter a brief description of condition that caused component to be replaced, DATE [INSTALLED ~ Enter date new com- ponent is installed, INSP - Enter stamp or signature of indi- vidual making the entry. Il, OTHER LOG BOOK FORMS THAT ARE (OR MAY BE) AFFECTED. A. PRIMARY INSTRUMENTATION SYSTEM ROAD MAP. Tf primary instrumentation aystem NA CD TTS A Pa R-3896~-11 Section HI transducers are replaced or deleted, make necessary changes in Primary Instrumentation System Road Map. (See figure 3-18 for in- structions. ) NOTE If flight instrumentation pressure transducers are replaced or de- leted, changes must also be made in the Post-Delivery Flight Instru- mentation Pressure Transducer Replacement Record, (See figure 3-28 for instructions. ) B, DELIVERED SERIALIZED COMPONENT ee ee a Pm and replaced, removed and deleted, or re- identified, make proper changes in Delivered Serialized Component Record. (See figure 3-24 for instructions. ) C. POST-DELIVERY COMPONENT CYCLE RECORD, if a @ component that requi requires a res a Post- Belivery Component Cycle Record 1s replaced, make necessary Post-Delivery Component Cycle Record changer. (See figure 3-31 for instruc- tions. ) D. AGE CONTROL LOG FOR COMPONENT SYNTHETIC RUBEER ITEMS, If listed com- ponents containing rubber items are replaced, make necessary entries in Age Control Log for Component Synthetic Rubber Items. (See figure 3-35 for instructions. ) Figure 3-27. Post-Delivery Serialized Component Replacement Record (Sheet 2 of 2) Change No. 4 - 6 August 1969 3-147 Section IIT R-3896-11 ° | POST-DELIVIRY PLIGHT IN: INSTRUMENTATION PRESSURE TRANSDINER ALPLACEMENT RECOHD I, GENERAL INSTRUCTIONS, NOTE This form will not appear in ali log books; this instruction applies only to log books having this form. Entries must be made in the Post-Delivery Flight Instrumentation Pressure Transducer Replacement Record whenever a flight instru~ mentation pressure transducer is replaced. fl. DETAILED INSTRUCTIONS. Complete rorm as follows: ITEM NO, - Enter item number listed in log book Delivered Serialized Component Record that corresponds to transducer being replaced. Hf transducer is not listed in log book Delivered Serialized Component Reoenrd, leave this calumn blank, ENGINE S/N __F-20XX Date 30 SEP 6a PART NO, - Enter part number of trans- ducer being installed. SERIAL NO. - Enter serial number of transducer being installed. TAP NO. - Enter tap identification number applicable to transducer being installed. PARAMETER (PRESSURES) - Enter param- eter name applicable to tap number in which transducer is being installed. CALIB, VOLTAGE - Enter initial, low- calibration, and high-calibration voltage output reading as obtained from flight instrumentation checkout console printer, or equivalent. COMMENTS - Enter reason for transducer replacement, INSP, - Enter stamp or signature of individual making the entry. Figure 3=: 28. Post-De -Delivery Flight Inst Instrumentation Pressure Transducer “Replacement Record Ne er A A RAL ESP I, GENERAL INSTRUCTIONS, The delivered Orifice Record lists all variable orifices that are installed in the engine at the time of delivery. The only post-delivery a ‘er- ation required on this form is the lining out of entries when a post-delivery change of a Hsted orifice is performed. Figure 3-29 3-148 Change No. 4 - 6 August 1969 A athe re rs er ee Il, DETAILED INSTRUCTIONS. Identify orifice that was replaced, line out all entries for this orifice. paragraph 3.7.4.8.) and correctly (Refer to 5 Delivered Orifice Record R-3866-11 —— No. 1 main LOX valve | RDO51-4085 016) opening line orifice No. 2 main LOX valve | RbO51—u035-016) opening line orifice 151-498 $0089 No. 1 min fuel vaive opening line orifice No, 2 masun fuel valve | RDG51-402%0089 opening line orifice #0251 -4098-007Y GG valye opening Jine orifice WD251-A13C BF Downstream GG Lox orifice 1, GENERAL INSTRUCTIONS, Intries must be made ir the Post-Deiivery Orifice Replacement Record whenever an orifice hsted on the log book L’ativered Orifice Record is cepluced, including ':.ose cases where the replacement does not involve an orifice diam- eter change. HM, DETAILED INSTRUCTIONS, Complete form as follows: NOTE If an orifice Histed on this form is subsequently replaced, line out the obsolete entries as outlined in para- graph 3.7.4.8. ITEM NO, - Enter item number listed in log book Deliverc.d Orifice Record that corresponds to o: ifice being replaced. ORIFICE NAME - Enter name of orifice being replaced. ORIGINAL PART NO, - Enter part num- ber of original orifice, the last four digits of which Indicate original orifice diam- eter, If Original Part No. column is not on the form, use Comments column and indicate “Orig P/N,” Figure 3-30. Post-Delivery Orifice Replacement Record POST-DELIVERY ORIFICE REPLACEMENT RANCURD WOW PAaT HO. 5.0161 | ag051-4085-0179 RD251-4085-0180 R25 1~4.683-00H2 KD251-1083-0052 hb251-4099-0097 RDO5 IA LIO-1 183 Section Lil en te ptt naiert enue ene ale an tall 3 LOCATION YB “DENTEFICATS Cowen Ts Oe No, J MIV Replaced per FCP FI—ité No, 2 MIV [Replaced per POP Fl—ihhf 14 Oct Kephaced per BU? Fi-44a Replaced per ECD Flu Replaced per KUP F144 Replaced per BUP F1-596 DATE mn 30 SEP 68 @ NEW PART NO, (or PART NO.) ~ Enter part number of new orifice, the last four digits of which indicate new orifice nominal diameter, @ LOCATION IPENTIFICATION CODE - Refer to log bovk Delivered Crifive Record and determine if orlfice being replaced requires a location identification code. Knter location identification code letters that correspond to orifice being replaced. COMMENTS - Enter reason for orifice replacement, NOTE Columns 7 and 8 may appear in reverse order on the form. & DATE ~ Enter date new orifice is installed. INSP (or INSPECTION) - Enter stamp or Signature of individual maxing the entry. Il. OTHER .OG BOOK FORMS THAT ARE (OR MAY BE) AFFECTED, A, DELIVERED ORIFICE RECORD. Le a re HE ee SY a ere If a listed changes in Delivered Orifice Record. (See figure 3-29 for instructions, ) Change No, 8 - 9 September 1970 3-148.A Section Ii h-38596-it + Sr Se eer ee es eee ee mer Lp so ENGE S/N ¥x! | OPERATIONAL DATA (HEAT EXCHANGER PERFORMANCE SUMMARY) MODEL aes Rada UXCHANGER Pak? nance GY sess LLL et HEAT £aC4AnGER SERISL NUML n ry3ty TES! NUMBER RSE ee ee Mik 7 — eS TEST EFFECTIVE DURATION SEC ho 4 BATA INTERVAL SEC TO SEC 55 -3x TURGINE EXHAUST GAS FLOWRATE TE ge yses. ‘aa ee TURGINE EWHAUST STATIC PRESSURE PSIA 2 MIT TURDINE EXHAUST TEMPERATURE ‘ t133.4 HEAT EXCHANGER LOX Flownare. SSS™S™S™S™S~S~SSS esc Sg HEAT EXCHANGER LOX 1.LET STATIC PALSSURE PSIA UR Soe meniuded MEAT EXC AANGER LOX INLET TEeiPERATURE F { Rel te auscuged HEAT EMCHANGEN GOX OUTLET STATIC PRESSUNE PSIA < 2: {32H 4 HEAT EXCHANMIER GOX OUTLET TEMPERATURE F 208.4 DIAMETER OF LOX COIL AIPASS CAIFICE wenes [@PB uo 17 O'ANMETER OF LOK COML IMLET ORIFICES INCHES ayy HELIUM CON OFERATING FLUID. = = , Se ma HELIUM COW. WET OPFRATION INTERVAL SEC TO SEC IGA y G-1lu.4 wEAT EXCHANGER HELIUM COIL FLUIG FLOWRATE LAS/S£C iN Bowe meesuded HEAT EXCHANGER MELIUM COIL INLET FLUID STAIIC PRESSURE PSIA 2 RM Nat co absuifed HEAT EXCHANGER MELIUM COIL INLET FLUID TEMPERATURE F > HEAT EXCHANGER HELIYM CON OUTLET FLUID STATIC PRESSURE psa 71. eee MEAT EXCHANGER HELIUM COL OUTLET FLUID TEMPERATURE r i UR) QIAMETER OF HEI UM COW, BYPASS ORIFICE UPSCHES 3 1: Le DIAMETER OF MELIUM COIL INCFT ORIFICES INLHES yA" 11, 4b WAS rd is “aes OAT Eo I GENERAL INSTRUCTIONS. & TEST NUMBER - Enter letters and/or numerals that indicate test facility or entries must be made on the Operational Data vehicle identification. (Heat Exchanger Performance Summary) form to record performance of the heat exchanger 4) TEST EFFECTIVE DURATION - Enter during engine tests conducted after delivery. effective duration of test to nearest 0.1 second. I]. DETAILED INSTRUCTIONS. a DATA INTERVAL - Enter elapsed effec- Coniplete form as follows: tive duration of test when data interval was started and terminated to nearest @ wear excHANGeR PART NUMBEK - 0.1 second. Enter part number of heat exchanger instalied on engine. @ TURBINE EXHAUST GAS FLOWRATE - Enter total propellant weiht flow 2) HEAT EXCHANGER SERIAL NUMBER - supplied to gas generator to nearest Enter serial number of heat exchanger pound per second. installed on engine, TN YR PL i rr Figure 3-30... Operational Data (eat Exchanger Performance Summary) (Sheet 1 of 2) 3-148B Change No. 7 - 28 April 1970 Baa R-3896-11 A A ST AY TURBINE EXHAUST STATIC PRESSURE - Enter absolute value of combustion gas static pressure at heat exchanger entrance to nearest 0. 1 psia. 8) TURBINE EXHAUST TEMPERATURE - Enter measured temperature of com- bustion gas at heat exchanger entrance to nearest degree fahrenheit. §) HEAT EXCHANGER LOX FLOWRATE - Enter weight flowrate of oxidizer through heat exchanger J.OX coils to nearest 0. 01 lb/sec. HEAT EXCHANGER LOX INGET STATIC PRESSURE - Enter words "Not measured”. @ HEAT EXCHANGER LOX (NLET TEM- PERATURE - Enter words "Not measured”. @ HEAT EXCHANGER GOX OUN'LET STATIC PRESSURE - Enter absolute value of oxidizer static pressure at exit of LOX coils to nearest pound per square inch absolute. @ ueat EXCHANGER GOX OUTLET TEMPERATURE ~ Enter meas ired temperature of oxidizer exiting from LOX coils to nearest degree fabrenhett, @ DIAMETER OF LOX COIL BYPASS ORIFICE - Enter diameter of LOX bypass orifice to nearest 0.001 inch. If ne ori- fice is installed, enter words “No orifice”. 15) DIAMETER OF LOX INLET ORIFICES - Enter diameter of orifices installed in inlet of LOX coils to nearest 0.001 inch. If no orifices are installed, enter words No orifices”. 16 HELIUM COIL OPERATING FLUID - Enter type of fluid being passed through heat exchanger helium coils during data interval. Section III @ HELIUM COIL WET OPERATIONAL INTERVAL - Enter elapsed effective dur- ation of test when helium cot! operating fluid started and terminated flow through helium coils tu nearest 0.1 second. if coils were flowed throughout test, enter 0.0 and effective duration of test. 18) HiEal EXCHANGER HELIUM COIL FLUID FLOWRATE - Enter words "Not meas- ured’, (eat EXCHANGER HELIUM COIL INLET FLUID STATIC PRESSURE - Enter words "Not measured’. 203 HEAT EXCHANGER HELIUM COIL INLET FLUID TEMPERATURE - Enter measured temperature of helium coil operating fluid entering helium coils to nearest degree fahrenheit. @) eat EXCHANGER HELIUM COIL OUT- LET FLUID STATIC PRESSURE - Enter absolute + lue of helium coil operating fluid static pressure at exit of helium coils to nearest pound per square inch absolute. @ HEAT EXCHANGER HELIUM COIL OUT- LET FLUID TEMPERATURE - Enter movasured temperature of helium coil operating fluid exiting from the helium coils to nearest degree fahrenheit. 23) DIAMETER OF HELIUM COIL BYPASS ORIFICE ~ Enter diameter of helium by- pass orifice to nearest 9,001 inch. If no orifice is installed, enter words "No orifice’. 24) DIAMETER OF HELIUM COIL INLET ORIFICES - Enter diameter of orifices inetatled in inlet of helium coils to nearest 0.001 inch. If no orifices are installed, enter words "No orifices". Figure 3-30A. Operational Data (leat Exchanger Performance Summary) (Sheet 2 of 2) Change No, 7 - 28 April 1970 3-149 Section {I R-3896-14 EE ST TT eT Api ein MODEL Fb POST-DELIVERY COMPONENT CYCLE RECORG COMPONENT NAME THRFR-WAY SOLENOID VALVE ASSY part NO © 558350 SERIAL NO 835N095 os H CCUFULATED ri 3 Pe ee NU. OF CYCLES & COMMENTS 2 rere me i el CNGINE SN. F-QOXX V-24024 ¥-20021 V-RA08% iW | C4 DATE ___30 SEP 68 1. GENERAL INSTRUCTIONS. k. Gimbal bearing | Entries must be made in the appropriate log 1. No. 1 thrust OK pressure switch | book Post-Delivery Compunent Cycle Record | whenever the components listed in paragraph II m, No. 2 thrust OK pressure switch ave cycled on an engine, excluding those cycles that occur during engine static firing. Refer n. No, 3 thrust OK pressure switch to section II for cycle defimtions and cycle limits. o. Checkout valye Il, DETAILED INSTRUCTIONS, p. Heat exchanger GOX outlet customer a a eonnect line Wherever one of the following components is cycled during performaace of a test or proce- q. Heat exchanger helium supply customer dure, make entries in applicable Post-Dellvery connect line Component Cycle Record: r, Heat exchanger helium return customer i. No. 1 main fuel valve connect line b. No. 2 main fucl valve s, Hydraulic supply customer connect iine c. No. 1 main LOX valve t. Hydraulic return customer connect line d. No. 2 main LOX valve Complete form as follows: e. Ga» generator ba)l valve @ DATE - Enter date component is cycled. f. Engine control valve eB TEST OR PROCEDURE - Enter a brief description of test or procedure being g. Ignition monitor valve performed during which component was cycled, h. igniter fuel valve NO. OF CYCLES - Enter nuinber of times component is cycled during test or proce- dure. When recording gimbal bearing and customer-connect line cycles, enter mag- nitude of gimbal angular excursion also. {, Bearing coolant control valve J. Redundant snutdown valve Figure 3-31, Post-Delivery Component Cycle Record (Sheet 1 of 2) 3-150 Change No. 4 - 6 August 19869 R-3896-11 Pa ee ee 4) ACCUMULATED NO, OF CYCLES - Enter sum of previous entry in this cohinin and current entry in No. of Cycles column (columu 3). When recording gimbal bear- ing and customer-connect line accumulated cycles, enter sum of current entry in No, of Cycles column and last entry in Section ff NOTE Entries numbered 6, 7, and 8 are completed to initiate a Post-Delivery Component Cycle Record for replace- ment components or to add new sheets to the log book. this column at same gimbal excursion. @ COMPONENT NAME - Enter name of @ COMMENTS - Enter reason component is cycled, cata AAS CLERGY SRY Yuba eee SPA rE EPGSSEES RSS? SPS SPORES PAIS component, PART NO, - Enter component part number. SERIAL NO, - Enter component serial number, ee ee EE Figure 3-34, Vost-Delivery Component Cycle Record (Sheet 2 of 2) Change No. 4 - 6 August 1969 3-151 Section Ol oe model Ft Ove ee UISCREPANCY 8, Du. ing post-modification and buildup a, checkout (heat exchaner LON coil leak test), leakage noted at H/E GOX out Slaw atatic seal monitor port. (ef Ven FOO8GGO, LTR 0272591) 9. During pustemadificatian cheehant, inert prefill check waive ATH, SF 4082305, failed ta open, (Ref UCN FOOGLG7 and UPR W9t1032) OISCREPANCY RECORD Seal replaced, 4 R-3896-11 at I Yh over P-20XX ENGINE S/N SS Mahe rere ACTION TAXEN 10, During static teat S-I0-4-7, thermal 1, Brackets repositioned und retorqued at MIF, [50 tie inaulation avatem brackets i320) and Oa FADNIG came Loose and dislodged. (Ref CBR V284237, CR ROTEI20) fi. Novvle extension HOGI aay SN anAett: Voatetvat S-IC9a <7 inspection reveala a nut a plate in indaning from Now t Unwil at Ias?, FRef TIER Uekanod, CCH \uli319) vA 2 oATE 14 APR 67 I, GENERAL INSTRUCTIONS, Significant engine discrepancies resulting in Unsatisfactory Condition Reperts (UCRs) or material review type action, discovered after engine delivery, are recorded in the Discrep- ancy Record. Entries must be made on this form to record engine discrepancies as soon as the discrepancy Is discovered. Il. DETAILED INSTRUCTIONS, Complete form as follows: DISCREPANCY ~- Enter a brief descrip- tion of discrepancy, and indicate date and time relative to engine tests conducted when discrepancy occurs. Enter number of UCR written against discrepancy. C2 | ACTION TAKEN - Enter a brief descrip- tion of action taken to clear discrepancy, Reference all Government cr Cortractor UCRs written against discrepancy. DATE - Enter date discrepancy is cleared. INSPECTION - Enter stamp or signature of individval making the entry, Ill, OTHER LOG BOOK FORMS THAT ARE {OR MAY BE) AF "FECTED. A. COMPONENT TEST RECORD, If discrep- ancy disposition required replacement of a component that has a Component Test Record (CTR), make necessary changes to forma in- volved, (See figure 3-19 for instructions. ) 3-152 Change No. 4 - 6 August 1969 POST-DELIVERY PERFORMANCE UN-. CERT ORY RECORD. If engine performance ‘uncertainty is affected by discrepancy dispost- tlon, make necessary Post-Delivery Perform- ance Uncertainty Record changes. (See figure 3-20 for instructions. ) C. RIGID-DUCT SPACER DIMENSIONS, If discrepancy disposition resulted in removal of components that require accomplishment of fit-check procedures, make changes on appro- priate Rigid-Duct Spacer Dimension form. (See figure 3-25 or 3-26 for instructions. } POS1-DELIVERY SERIALIZED COMPQ- NENT YT REPLACEMENT RECORD, Ii discrep- ancy ancy digposition resulted in replacement of a serialized component, make entries in Post~ Delivery Serialized Component Replacement Record. (See figure 3-27 for instructions. ) E. POST-DELIVERY ORIFICE REPLACE- MENT REC RECORD. if discrepancy disposition resulted in an orifice replacement, make entries in Post-Delivery Orifice Replacement Record, as necessary. (See figure 3-30 for instructions. ) Figure 3-32, Discrepancy Record R-3696-11 wooer Fr) @ CYPE OF INSPECTION ere ee cree i. Thermal inau'’ation brackets jortallation per Rocketdyne draving 145011 2. FPIR PI-28A — Ite place- ment of oxidizer pump pedmary oxidizer aval eo RESULTS nF, ALO, 842 na noted on sheet No. 1K501t. (TIS S/N 17-5) %. Hecedving inspection (visual) 4, Post=modification and buatdup checkout See Discrepancy Record, FFI FI-33 = Tnapee tion of Jebox support atrat rod ends wD were replaced, G&G. Postendification checkout Seco Diacrepancy Recard, 7. FFI FI-AY = Re plaree ment and isp af engine control valve opening, ‘toning, and iUSt, engine supply filters Filtiera replaced, H, Main injector lospection!) No diserepancteg noted, %, Tuspeetion of FIRC return howe per FFIR F1-378 (leak check) 16, Inspection of renoved FI return hose asay & eS by oT all packing per EFIR FI-378 Nu leakage No diacrepancien noted. I. GENERAL INSTRUCTIONS. The Inspection Record is used to record engine inspections and inspection results, except engine closure humidity indicator inspections. Humidity indicator inspections are recorded in individual records that are not associated with the log book. Tl. DETAILED INSTRUCTIONS, Complete form as follows: ° TYPE OF INSPECTION - Enter name or description of inspection. If inapection requirements is an Engine Field Ingpec- tion Request (EFIR), enter EFIR title and number upon receipt. RESULTS - Enter a brief description of inspection results. Make note of any discrepancies discovered and enter these in Discrepancy Record, Figure 3-33, nnn RR NE LS FR Lf itnd INSPECTION R&CORD a re A A he cD Inatalled items 195, 196, 342 thru 535, $12 thrn 81%, and #2] thro 3 of draving feplaced oxidizer pump primary seal No significant discrepancies noted, Ttem 4. Two rod ends RE13)]-7001-0003 and one rod end RELSL+~7008-0003 found discrepant and Ttem 4, Section HT F-20XX ENGINE S/N Qn OF INSPECTION DATE NAR Rocketdyne fh. (anoga Park MAR Rocketdyne 28 Jun | Canoga Park 67 RO-MAF 97 Ty] 6? TW-MAF & (et 7? RD. MAF Ib Det RO-MAP Rn-MAF RD-MT F W-Ml + IO~MTF OATE APR 7 & PLACE OF INSPECTION - Enter com- plete designation of facility at which inspection {s conducted. DATE - Enter date inspection is com- pleted. INSPECTION - Enter stamp or signature of individual making the entry, Til, OTHER LOG BOOK FORMS THAT ARE. (OR MAY AFFECTED, A, DISCREPANCY RECCRD. Enter any dis- crepancies discovered during performance of engine inspections in eaaiene Record. (See figure 3-32 for instructions. ) SL SA CY A SN RD | Inspection Record Change No. 4 - 6 August 1969 3-153 Section I R~389 3-11 F} TUREOPUMP PRESERVATION RECORD yogi SAGINE OE. Omen Qeacmmm Qewn Om 4089893 RAU220--7264, P-1 Fugine Acceptance Post teot 436.016 8 Mar 67 Test Requireaents and Procedures 4069894 b5-11789-100, 1.29 PF] Turbopump Preservation Poat tant S-IC-6-7 19 Dec 68 “CATE 14 APR 7 I. GENERAL INSTRUCTIONS, SPECIFICATION TITLE - Enter title of document utilized to accomplish preser- The Turbopump Preservation Record must be vation procedure. updated whenever preservation of the turbo- pump is accomplished. ra TEST NO. OR OPERATION - Enter time F 2 : preservation procedure is completed H. DETAILED INSTRUCTIONS. {include static test number, if applicable). Comolete form as follows: & INSPECTION - Enter stamp or signature @ TURBOPUMP SERIAL NO, - Enter of individual making the entry. turbopump serial number. @ APPLICABLE SPECIFICATION - Enter @ DATE - Enter date preservation proce- number, including revision or change dure is completed. number if any, of document utilized to accomplish preservation procedure. i rn a a Figure 3-34. Turbopump Preservation Record 3-154 Change No, 4 - 6 August 1969 R-3896-11 Section ITI ecutnimatenitamemnn tented tadadt aude T AGE CONTROL LOG FOR COMPONENT SYNTHETIC RUBBER ITEMS Ewame s/n ___Fr20xKK INSTALL REPLACE- | INSPEC - D.2 30 SEP 68 1. GENERAL INSTRUCTIONS, @ wera t DATE - Enter date of installa- tion of rubber ite:as into component. Entries must he made on the Age Control Log for Component Synthetic Rubber Items form REPLACEMENT DATE - Enter date com- for all compunents listed that contain synthetic ponent rubber items niust be replaced. rubber items, when the life of synthetic rubber items expires or components are overhauled @ INSPECTION ~ Enter stamp or signature or replaced. of individuai making the entry. DATE REPLACED - On existing entry, enter date component is overhauled or replaced and line-out obsolete entry as outlined in paragraph 3, 7.4.8. H. DETAILED INSTRUCTIONS, Complete form as follows: E ~ Ente : @ PART NAME ~ Enter name of component IM, INSPECTION REQUIREMENTS, PART NO, - Enter part number of component. Perform oldest assembly/installation date inspection as outlined in paragraph 3.1, 3, SERIAL NO, - Enter serial number of component. MFG CODE - Enter code number of component manufacturer, SPEC NO, - Enter applicable Contractor or Customer document number that speci- fles age control for component rubber items. ——r —, Figure 3-35, Age Control Log for Component Synthetic Rubber Items Change No, 13 - 4 April 1972 3-155 Section Il R-3896-11 cn A | LOUSE EQUIPMENT FLIGHT INSTALLATION RECOAD PART NAHE PART NG. TC EXTENGION GAS COOLED oe 209210 COX OUTLET GUCT £06070 HYDRAULIC SUPPLY SuCT 406071 HYDRAULIC RETURN DUCTS 406072 - MELIUM SUPPLY DUCT 404073 HELIUM RETUHN DUCT 406075 TP LOX SUAL PURGE HOSE ASSY NA5~26831 LOX DOME PURGE? HOS! ASSY AS P6882 K.E.21 I, GENERAL INSTRUCTIONS. Entries must be made in the Loose-Equipment Flight Installation Record whenever a loose- equipment item listed on the form is perma- nently installed for flight. If an installed item is subsequently replaced, entries are also required. Complete form as follows: NOTE Codes listed in Configuration Code column indicate the location where the part will normally be installed. Codes V or J indicate MAF or KSC, respectively. Code H indicates post-utatic test installation at MAF (during refurbishment). a ee. TC JACKET PREPILL HOS ASST HA5=26883 CO FUEL Md AND THERM INS PRG hAS=26884 1 HOSE 2357 AIRING HARHESS ASSY, HIGH VOLTAGE} 502932 1 IGN TYFRS TGNITER ASSY, HIGH VOLTASE 65190 COVER, SUEPORT, PURGE HOLE 651578 1 CO¥nR, SRACKL?, HYDRAULIC 552297 = PAD R229 Jeu 4 COVER, BRACKAT, RETURN DUCTS 651246 2 ENGINE S/N F-20XX CONF IG- Mai Se QUANTITY ea. NSTALLATION COMMENTS cope | bATE INSPECTION : DATE a5 PED 69 e Listed part names preceded by one asterisk (*}are applicable to out- board engine installation only. Those preceded by two asterisks(**) are applicable to inboard engine In- stallation only. e This figure does not duplicate the entire loose-equipment list that ap- pears in the log baok. INSTALLATION - Enter date listed item is installed and stamp or signature of indi- vidual making the entry. @ COMMENTS - If items listed are replaced or deleted subsequent to installation, enter reason item is replaced or deleted refer- oncing any supporting documentation (UCR, UER, etc), Figure 3-36. Loose-Equipment Flight Installation Record (Sheet 1 of 2) 3-156 Change No. 4.- 6 August 1969 R-3896-11 Section I te tr ls era Ill. OTHER LOG BOOK FORMS THAT ARE B, POST-DELIVERY SERIALIZED COMPO-, ———— (OR MAY BE) AFFECTED, NENT REPLACEMENT RECORD, Update Post Delivery Serialized Component Replace- A. DELIVERED SERIALIZED COMPONENT ment Record when listed items of installed RECORD. Make entries in Delivered Serial- loose equipment are replaced. (See figure ized Component Record when listed items of 3-27 for instructions. ) louse equipment are installed on engine and subsequently replaced, (See figure 3-24 for instructions. ) — ner era er een Figure 3-36. Loose-Equipment Flight Installation Record (Sheet 2 of 2) Change No. 4 - 6 August 1969 3-157 Section II R-3896-11 Fedoyn 5°] TOTAL TIME ~ aeconde HOOE La! TRANSFER RECORD ENGINE 3/N TIME SINCE NEw OR OVERHAAED @ ORGANIZATION AND LOCATION O eeeeemaneal WR Rocketdyne, Canoga Park 10 Dee G35 17 seconds 3 Jan 06 10 San 66 The Bocing Congeny. MAP avr onda err onda log Book Audit | Log Book Audit Sav Ob ab 2 Now Of OM Nov 67 7 seconds The Boeing Company. MSEC j Navy seconds log Hook Audit log Book Audit Nov 7 ec 47 weronds wevonds The Roving Company, MAF Log Book Audit Zi. a.2 CATE 6 DR G5 1. GENERAL INSTRUCTIONS, DATE - Enter date that engine is shipped or received. lf engine is launched, enter Entries must be made in the Transfer Record launch date. whenever engine custody is transferred or the engine is shipped, received, or launched. In 4) TIME SINCE NEW OR OVERHAULED - addition, entries must be made to record log Enter accumulated effective duration of book audits performed during shipping, re- all tests on engine since new or overhauled, ceiving, and prelaunch operations. to nearest 0.1 second. Obtain accumu- lated time from Engine Test Record. 1, DETAILED INSTRUCTIONS, (See figure 3-22.) Complete form as follows: & TOTAL TIME - Enter accumulated effec- tive duration of all tests on engine inue- ORGANIZATION AND LOCATION - Enter pendent of overhaul. organization designation and location of organization responsible for shipping or ML. one LOG BOOK FORMS THAT ARE receiving engine. If engine was launched, (OR MAY BE) AFFECTED. enter '‘Launched”" as last entry in (his column. If a log book audit was per- 4. CONFIGURATION RECORD. Review the formed, enter ''Log Book Audit." Configuration Record and c complete entries, if necessary, to make Configuration Record reflect INSPECTION - Enter stamp or signature engine configuration at time of transfer or of individual making the entry. In the launch. (See figure 3-23.) case of a log book audit, enter date and stamp of Contractor representative mak-~ ing the entry and Government representa~ tive verifying accuracy and compicteness of log book. ee Figure 3-37. Transfer Record 3~ 158 Change No, 4 - 6 Auguai 1969 R-3896-11 APPENDIX OPERATING INSTRUCTION CHANGE NOTICES Operating Instruction Change Notices (OICNs) are issued from time to time to communicate important and urgent information concerning the equipment covered in this manual. These OICNs bear an identifying number and should be filed in this Appendix. OICNs directly affect the data in this manual and will be incorporated into this manual during a future updating effort. An OICN Record ta issued periodically to indi- cate the status of OICNs issued for this manual. The status of each OICN is indicated in the "OICN Status" column. For active OICNs, no status is entered. For incorporated OICNs, "Incorporated" is entered. Upon receipt of an OICN, make an appropriate reference to the OICN in the margin next to the data changed, and enter the applicabie informa- tion in figure 2 of the Introduction. OPERATING INSTRUCTION CHANGE NOTICE RECORD This OICN Record indicates the status of OICNs shall be removed from the Appendix and issued for Technical Manual R-3896-11. OICNs destroyed. which have been incorporated into the manual OICN OICN Number Dated Description Status 1 24 June 1969 Deletes post- manufacturing checkout Incorporated activities at MAF and integrates them with pre-static checkout activities at MTF. 2 9 October 1069 Adds fuel overboard drain system isv- Incorporated lation requirements and fuel feed system Grain requirements. 3 1 Atgust 1969 Revises torque requirements for igniler Incorporated installation. 4 12 December 1969 a. Adds a new activity for leak check Incorporated of fuel vatves and gas generator ball valve after aclmitting fuel, consolidates activities for admitting fuel, and changes sequence constraints for admitting fuel and prefill. b. Adds reusability requirement for K-seais used on seal monitoring port plugs and pressure-actuated (Naflex) seal used at oridizer overboard drain line flange (thrust chamber to nozzle exten- sion joint). c. Revises turbopump LOX seal purge sequence requirements. Change No. 6 - 10 February 1970 A-1 APPENDIX OICN Number R- 3896-11 Description rr er i a d. Adds a constraint to vent turbine system! during uninstalled-engine testing at MAF when LOX dome and gas genera- tor LOX injector purge is pressurized, when fuel or LOX system is pressurized, and when fuel overboard drain system 15 pressurized. e. Clarifies that pressure specified in turbopump bearing coolant system leak test ig supply pressure, not moni- tor pressure, and clarifies vapor emission from thrust chamber exit during thrust charober fuel jacket flush. f. Adds MD coding for engine environ- mental temperature transducer, g. Changes turbopump r.. “servation frequency from 2 years to 3y urs. h, Changes method required for leak- testing thrust chamber external tubes when stage is in horizontal position. i, Changes requirements for launch abort recycle, and deletes visual inspec- tion activity subsequent to leunch abort, j. Adds special constraints and re- marks specifying method for determining fuel vulve nose and skirt seal leakage and requiring LOX system pressurization during fuel feed systein leak test at MAF subsequent to static test, and at KSC. k. Revises component cycle definitions. l. Changes igniter test voltage require- ment. m. Allows reuse of slave engine hard- ware when static-testing engines at MTF, n. Deletes instrumentation requirement not applicable to engines covered 1 this manual, specifies use of hypergol system test tnol 9021279, clarifies LOX dome flushing requirements, and corrects typo- graphical errors in titles and references. A-2 Change No. 6 - 10 February 1970 OICN Status oICcN Number 4 (cont) at ce) 10 12 24 September 1969 11 December 1969 3 Octcver 1969 11 December 1969 16 October 19489 22 October 1969 R-3896-11 2 TR AR RA A A Description o. Adds sequence requirements for purge systems, adds a thrust chamber liquid-leak-test constraint, deletes specific solvent requirement for nozzle extension flange and seal groove clean- ing, and revises electrical control sys- tem sequencing and safety circuit requirements. p. Adds a constraint that requires Engine Contractor « smcurrence and that specifies minimum allowable clearance, installation, and clamping requirements when hardware, other than engine hard- ware, is installed on the engine. q. Changes fuel admittance require- ments to permit loading of fuel with pre- valves open. Substitutes lubricant grease RBO140-012 (Rocketdyne) for KEL-F 90 (Minnesota Mining and Mfg) us specified, Adds requirement to perform an ignition monitur valve poppet position verification test. Corrects procedures for oressurizing and depressurizing hydraulic system for uninstalled engines and adds closure installation for vertical-enyine removal. Revises test pressures required during heat exchanger LOX system leak test for uninstajlod engines, and at MTF, for installed engines. Adds reinoval and installation of gas generator seal monitoring vent hoses during exhaust system leak test at KSC. Adds a procedure for gaining access to fuel jacket purge quick-diseonrect on No. 1 fuel valve when thermal insula tion «8 installed, APPENDIX RS RL EY UE EY Sree OICN _. Status TS Incorporated Incorporated Incorporated Incorporated Incorporated Incorporated Change No. § - 10 February 1970 A-3 R~-3896..11 SS A a SR, AF eh een FPSO Description Adds requirement to perform checkout valve engine return switch verification, adds control system \ 9'*.'e level for load conditions, and ¢. es igniter harness measurement requirement. Provides alternate types of polyethylene material which may be used to make plastic bags to be used during fuel over- board drain system isolation procedures. Revises cocoon purge sequence reqvire- ments and engine environmental tempera- ture requirements, Incorporates validation comments in turboputnp preservation procedure for engines not incorporating MD145 change and in live- and expended-igniter re- moval procedures. Adds requirement to inspect specified engine ju:nts, te make sure that joint closures are removed before static test or launch, and deletes the security requirement for the thrust chainber throat security closure lock. Adds requirement to perform ignition monitor valve poppet position verifica- tion after static test or launch abort, changes cerialized component log book entry requirements, deletes 28 14 vde electrical requirement from section [, and changes hydraulic control system constraints. Revises engine storage requirements and mits. Updates preservation procedure for serics lube engines to include use of Scavenge Pump G2039. Adds hypergol cartridge serviciny procedures and changes hypergel curtridge Installation procedures, Adds hypergol cartridge restoration requirements and updates hypergol cartridge repackaging requirements, Updates turbopump preservation requirements for series lube engines to include the use of Scavenge Pump APPENDIX “OcN > Number Dated 13 29 December 1969 14 12 Novemher 1969 16 23 March 1970 17 » December 1969 19 14 April 1970 20 25 March 1970 22 9 April 1970 23 9 January 1979 24 4 february 1970 25 22 May 1970 26 25 June 1970 G2639. A-~4 Change No, 8 - 9 September 1970 le OICN Status Incorporated Incorporated Incorporated Incorporated incoyvporated Incorporated Incorporated lnecorpourated Incorporated Incorporated incorporated rear ae in Number a Dated ; 27 29 June 1970 28 29 June 1970 29 13 February 1970 30 3 March 1970 31 30 September 1970 R-3896-Li Description Amends joint leakage acceptability criteria and establishes standard leakave monitoring techniques, Deletes the requirement for igniter checkout after installation, deletes the resistance reqtirement when igniter harness continuity i3 verified, changes the thrust Ok pressure swilch leak-test pressure level, changes the hydraulic control system leak-test pressure requirement, chenges the valve timing-test cycle requirement, and adds the thrust chamber internal tube leak test, A.dds instructions for maintaining the Operational Data (Heat Exchanger Performance Summary) Geletes cquivalent milliseconds from vibration safety cutoff verification test, lowers the tarque value of the cross-to-lateral drain tube, and adds 2 new method for securing bags during fuel overboard drain system isolation. Deletes the ordnance storage require- ment at MAF: corrects an activity requirement during storage at MTF; clarifies hydraulic component leakage into fuel averboard drain line; adds nitrogen purge line requirement for thrust chamber nozzle extension re- moval and installation; specifies that whe using ovcrational low-level LOX dome and gas gencrator LOX injector purge for LOX dome and gas generator LOX injector fiush, purge must be r-aintained for a minimum of 15 minutes; changes operational low- level and high-level LOX dome and gas generator J.OX injector purge sequencing requirements; updates sequencing requirements for thrust chamber fuel jacket purge systems and hypergol servicing purge system to agree with section I requirements; und corrects a typographical error. APPENDIX OICN Status Incorporated Incorporated Incorporated Incurporated Incorporated Change No, 9 - 2 December 1970 A-5 APPENDIX OICN Number 32 34 35 36 Dated 30 September 1970 29 April 1970 5 May 1970 30 September 1970 18 June 1970 30 September 1976 A SS a R-3896-11 Description Adds a requirement to inspect igniters before performing the igniter test, adds a requirement for performing an igniter thread inspection, and adds a remark specifying that an igniter must be in- stalled in a protective device that will prevent injury to personnel in event of accidenta} firing of an igniter during testing. Requires use of a plastic cap on the pressure switch checkout connection and corrects the part number of the alternate plug used in the gas generator igniter bosses, Simplifies the procedure for isolatirg the oxidizer dome purge check valves, clarifies the use of shorting caps on high-voltage igniters, and adds » cau- tion when using a deep-well socket for torquing igniters., Deletes the requirement for gas generator injector purge check valve reverse-flow leak test and LOX dome purge check valve reyerse-flow leal: test at KSC, and adds an exhaust system leak test at KSC. Adds a procedure for inspecting var- iable orifices to determine that their actual size is within machining toler- ance of the variable orifice nominal siae recorded in the Engine Log Book, and changes the Engine Log Book in- structions to specify that the last four digits of an orifice part number recorded in the Engine Lov Book tndi- cate the orifice nominal diameter. Updates the tube alinement require- ments figure to add new tubes, joint locations, and allowable mits. It algo updates various data in the figure to make it compatiole with other man- uals and specifications, A-6 Change No, 9 - 2 December 1970 CN a EE OICN Status Incorporated Incorporated Incorporated Incorporated Incorporated Incorporated ~OICN ~ Number Dated a tt er tp pe nu TU sf 38 8 July 1970 49 6 November 1979 40 3 February 1971 41 23 February 1971 42 2 Ostober 1970 44 § October 1970 45 2 November 1970 R-3896-11 Description Adds a procedure for installing plastic bags on oxidizer and nitrogen purge overboard drain lines, to permit venting of drain lines when turbopump LOX geal purge is applied when rotating the stage to the horizontal position. Adds thermal insulation damage limits. Standardizes fuel loading requirements at MTF and KSC; deletes 1,000 psig LOX dome and gas generator LOX injector purge as a redline requirement; deletes turbopump LOX seal purge pressure requirement with fuel in engine: and deletes hydraulic pressure requitement with fuel or prefill in engine, Extends turbopump preservation life to five years, deletes requirement for using only KEL-F-90 on the throat plug shaft threads, adds new limits for flex hose braid damage due to impact, deletes reference to variable or fixed when re- jerring to the gas generator upstream and downstream orifices, and adds closure RX20700 as an alternate to the thrust chamber throat security closure, Corrects the lubrication material spe- ecified for hypergol cartridge container inlet threads. Adds a method for supporting the pressurizing hose attached to the thrust vhamber throat plug seal, and corrects paragraph references to engine envi- ronmental cover installation, thrust chaniber throat security closure installa- tion and removal, thrust chamber throat plug installation and removal, and turbine exhaust exit pressure teat fixture ingtalla~ tion and removal. Provides the option to blank off the igni- tion monitor valve senge tube during the ignition monitor valve diaphragm leak test for uninstalled and installed engines, specifies that no leakage ia allowable at the ATMOS REF port during the ignition monitor valve diaphragm leak teat for installed engines, changes MTF to MAF in uote in exhauat system Jeak test for installed engines, and specifies that vent hoses be disconnected at the combustor end instead of the furbine end during the exhaust system leak teat for installed engines. APPEN Status Incorporated Incorporated Incorporated Incorporated Incorporated Incorporated lacorporated Change No. 11 + 6 May 19%1 OICN DIX APPENDIX R-3896-11 OICN Number Dated Description 46 4 November 1970 Adds a 10 +1 peig leak test of thrust chamber 4% 48 49 30 53 84 55 59 A-8 internal tubes between the throat plug and the thrust chamber exit. 16 August 1971 Adds a constraint which limits the period of time prefill fluid can be retained in the thrust chamber fuel jacket and replaces damage limits for the nozzle extension external reinforcing bands. 15 February 1971 Revises the detail instructions for making entries on the engine test record form in the Engine Log Book, 24 May 1971 Revises the test requirements and Hmits for the heat exchanger flowmeter transducer and the turbopump speed transducer. 20 July 1971 Updates applicable specifications to latest amendinent number, revision letter, and revision date, 25 October 1971 Relaxes turbopump preservation requirements, 25 July 1971 Updates torque requirement for plugs in ‘aps KF6d-2, KF%a-1, and IF2 and adds procedures for use of test plate T-5047892 during LOX dome and gas generator LOX injector flushing, 16 June i971 Updates seal monitoring port plug require- ments and changes exhaust system leak-test procedures to be compatible with requirements in secticn I, 15 August 1972 Relaxes gas generator leak test requirements. 13 July 1971 Updates seal monitoring port plug reguirements and changes exhaust systern leak-test proce- dures to be compatible with requirements ijn section I. 4 August 1971 Permits use of an equivalent simulator when hypergol simulator T-5029716 is specifled, adds the use of a hypergol simulator during fuel feed system leak test, and deletes a note and clarifies a plug removal requirement during the exhaust system leak test, 15 August 1972 Updates engine storage requirements and adds engine atandby requizements to be compatible with existing field operating requirements. Change No. 14+ 9 October 1977 ‘ Incorperated Incorporated Incorporated Incorporated Incorporated Incorporated incorporated Supers 2ded by OICN No, 5% Incorporated Incorporated Incorporated Incorporated 63 64 65 67 63 6 March 1972 29 November 1972 81 March 1972 5 April 1972 24 May 1972 17 October 1972 13 June 1972 R-3896-11 Adds a requirement to perform a pneumatic Description ns ae leak test on the thrust chamber after LOX dome flushing; changes the DC control system power requirements; updates appli- cable specifications to include current amendment number, revision letter, and revision date pertaining to leak-test com- pound and MSFC standara specifications; and adds a requirement to actuate the hypergol manifold switch after performing ignition monitor valve diaphragm leak test. Adds an inspection to determine compat- ibility between date entered in Engine Log Book and date stamped on a metal strip for OLDEST ASSEMBLY/INSTALLATION DATE, Incorporates the requirer nt to use desiccant RBOQ295-001 (Rocketdyne) in engine closures instead of desiccant MIL-D-3464, Type I, Requires drainage of the ignition monitor valve sense line after thrust chamber fuel jacket trichloroethylene flush and changes the hyJdraulle pressure requirement when admitting fuel to the engine, Adds engine requirements after a lightning strike. This change extends turbopump preservation frequency requirement from every 5 years to every 10 years. Reduces pressure limit for low-pressure gases. Change No. 14 - 9 October 1972 APPENDIX Incorporated {ncorporated Incorporated Incorporated Incorporated Incorporated Incorporated A-9/A-10 N. DLUIGILIAN 588 ~ CALG CODE IDENT NO. 02602 DATE _3 January 1973 PAGE J OF__2% OPERATING INSTRUCTIONS CHANGE NOTICE T) PROPOSED x] APPROVED NO. .____ 89. REN Roeser haan weer water! 1. ar Sm pm, Laem me ter, - ECP NO, 2. ENGINE OPERATING INSTRUCTIONS 3. PAGES AFFECTED _F 1-938. NO, _2-3896-14 As listed 4. EFFECTIVITY §. CONTRACTUAL AUTHORITY* Engines F-2029 Supplemental Agreement No. 150 to Contract through F-20098 _NAS8-25156, dated 22 December 1972 6. CHANGE This change updates storage preparation for uninstalled and installed engines to re- quire that gas generator igniter port closures, actuator holding pin attach point closures, and oxidizer dome accelerometer hole screws be left installed during engine storage, On page 1-71, paragraph 1.4.1, change step 1B as follows: 1B. Verify that gas generator igniter port closures, actuator holding pin attach point closures, and oxidizer dome accelerometer hole screws are installed; then install protective closures on oxidizer overboard drain and nitrogen purge overboard drain line exits, hypergol coutainer, and elec- trical connectors, Ali other covers and closures except as noted in this step and in steps j and k are to be removed, Including the gimbal bearing boot and the fuel overboard drain line exit. On page 1-72A/1-728, paragraph 1.4.2, step mA, change substep | as follows: (1) Vertfy that gas generator igniter port closures, actuator holding pin attach point closures, and oxidizer dome accelerometer hole screws are installed; then install protective closures on oxidizer overboard drain, fuel overboard drain, and nitrogen purge overboard drain line exits, hy~- pergol container, and igniter harness electrical connectors, Ad! other covers and closures except as noted in this step and in step k are to be removed, including the gimbal bearing boot, *This document shall be considered as a preliminary OICN until contractual coverage is received and noted in this block. Deka as ota Sect anreniateteehietin tol CODE IDENT NO. 02602 DATE _.3 January 1973 _ + x | ee OPERATING INSTRUCTIONS PAGE 2 OF 2. CHANGE NOTICE ECP ENGINE OPERATING INSTRUCTIONS OICN NO. —E1:938 NO, R= 3896-11 NO. .-.69 a A a ENE et LR tre ne eR tL A EA ATR I af ES Ye SRE ANT 1 ar Tg? i Eile PE AAO SP re mB, For engines stored ina vertical stage, verify that gas generator igniter port closures, actuator holding pin attach point closures, and uxidizer come ac~ celerometer hole access hole screws dre installed; then install protective closures on oxidizer overboard drain line and nitrogen purge overboard drain line exits, hypergol container, and igniter harness electrical] connectors. All other closures except 2s noted in this step and in step k are to be removed, including the gimbal bearing boot and fuel overboard drain Hne exit. Install) suitable drainage line on fuel overboard drain line exit, and route line exit so that leakage flows externally from engine. On page 2-10A, paragraph 2.24.3, step m, change substep 2 as follows: (2) Verify that drain bags are installed, or remove and replace fuel overboard drain system bags with drain hoses and route hoses so that leakage flows externally from engine, SPENT Pete pee Pree ic, Starr ah LA 2 APE 0 mY RE EEF A AT EA HY EM NRE TONE Tei Aee aertendy MEY SEL Pees RTE OH eatin tSry I Ar wren a PembvemS? — maar dnc aes ine WAT al tr are HR Ha PR Dt I PES eS Yt TRY CODE IDENT NO. 02602 DATE _i2_ March 1973 PAGE _1L_OF_2. OPERATING INSTRUCTIONS CHANGE NOTICE PROPOSED APPROVED NO. ___.2aRh Ne a NN A LS Ee SA A NN I A A Em Ar i. ECF NO. 2. ENGINE OPERATING INSTRUCTIONS 3. PAGES AFFECTED ‘F1--927R1 NO. _2-3896~11 ___As listed a a A a EN ns SA A RES OO 4. EFFECTIVITY 5. CONTRACTUAL AUTHORITY* Engines F~2029 Supplemental Agreement No. 16C to Contract ___ through Fo2098 | CNABE 25156, dated 5 March 1972 00 6. CHANGE This change: (1) adds a acheduled authorized field activity to verify that four-way solenoid valve replacement haa been accomplished within the 12 mouths preceding lauich; (2) updates detail requirements changing RP-l fuel to prope} tant tereaene to be compatible with applicable specifications list aa amended by supplenental agreement No. 55 to the contract; (3) adds acceptable shelf life for aynthetic rubber soft goods and changea installed lite of synthetic rnbber anft goods from 32 quarters to 40 quarters; and (4) updates applicable epecification to include current amendment number, revision letter, and revision date of propellant oxygen. Qn page 1-2, figure l=], between Activity Number 6A and "ELECTRICAL TESTS", add activity number 68, titled Four~way solenoid valve replacement verification, and in column f, add paragraph number 1.1.12C, *This document sha)! be considered as a preliminary OICN until contractual coverage is received and noted in this block. Pe NA Im Hii em POURS SR Hi UIT” hrs ORS TEPER, SPB state ened n ded dn dates heeded lan nigiemat RAT PETE EEE Pe frglt® Mane A sane of CODE IDENT NO. 02602 DATE 12 March 19730 PAGE 2. OF 2 OPERATING INSTRUCTIONS CHANGE NOTICE ECP ENGINE OPERATING INSTRUCTIONS OICN NO. F1~927Ri NO. B-3896—)1.. NO, 22h A Ft ee A TT EP On page 1-24), add paragraph 1.1.12C as follows: Special Constraints Paragraph Activities Requirements Limits nd Remarks 1,1.126 FOUR-WAY Verify that Within Replacement valve SOLENOID four-way the 12 soft goods must VALVE solenoid valve nonths have been replaced REPLACEMENT is replaced preceding and the valve VERIFICATION per EFIR Fl-62. lannch. tested with hydraulic fluid MIL~H-5606. On page 2-4, paragraph 2.1.5 aud page 2-4, paracraph 2.1.6, step a, change HPo]_ fuel (MIL-R-25576)_ to srapeilant kerosene (MiL-P-25576).. Qn page 2-20, replace the text of paragraph 2.4.7 with the following: The maximun acceptable shelf life of uninstalled synthetic rubber soft goods is 12 quarters. An age control log for components that covtain aoft goods is provided in each Engine Log Book. If it becomes neceasary to replace a component that contains synthetic rabber soft goods, the Engine Log Book age control log muat he updated to reflect the replacement date. The replacement dite is defined az the installation date of tne synthetic rubber soft goody in the component plus 40 quartera. On page 2-25, paregraph 2.5.6, stone, Materia) colum, chenge Fuel (RJ-] and Pol) to Fuel (BJ~-i_ and propellant kerosene}. On page 2~55/2-56, paragraph 2.7.1, change information pertaining to the followiig apecification as follows: MIL~P+-25508E Propellant, oxygen Amendment 1 30 April 197] Po Renee CHa ST A PTR POP Est ren) PRT A a eA VN eA AS ao tate CERO TR ES CODE IDENT NO. 02602 DATE _3 May 1973 PAGE 1 or__3. OPERATING INSTRUCTIONS CHANGE NOTICE PROPOSED APPROVED NO. 70 1. ECP NO, 2. ENGINE OPERATING INSTRUCTIONS 3. PAGES AFFECTED F1-939 NO, _2-3896-11__ ___As listed 4, EFFECTIVITY 9. CONTRACTUAL AUTHORITY* Engines F-2029 Supplemental Agreement No. 168 to through F-2098 6. CHANGE This change adds a constraint that must be observed when thermal insulation panels are removed and reinstalled during prelaunch operations; and constraints that must be observed when specified plugs, igniters, and the hypergol cartridge are installed, Since they cannot be leak tested after installation. On pages 1-2, 1-4, 1-5, and 1-7 through 1-9, figure 1-1, eplace oxisting single asterisk footnote with the following: ~~ ome * Activity requires removal and installation of thermal insulation panels, (Refer to section If for panel location.) Two persons must inspect, and record by separate buyoff, final prelaunch installation of thermal insula- tion panels to verify that panels are correctly installed, torqued, and safetywired. On page 1-70, paragraph 1.3.43, Special Constraints and Remarks column, add constraint as follows: == fa Before installing plug and K-sea! in the LOX system port used to pressurize the j thrust chamber, visually verify that K-seal, plug, and engine port sealing surfaces are free of foreign particles, nicks, scratches, and other imperfections that could impair sealing and that plug and engine port threads are free of damage. During installation, verify that K-seal is correctly installed on plug and centered in engine port countersink before torquing plug. Two persons must inspect, and record by separate buyoff, that plug and K-seal are correctly instaUed, torqued, and safetywired. Record piug actual torque value. *This document shall be considered as a preliminary OJCN until contractual coverage is received and noted in this block. TEE om tote tte Rata tas a RN TLL OLN ITE THN ENCE iis ARTE ESA OUP RRE FOE © CODE IDENT NO. 02602 DATE _3 May 1973 7 3 OPERATING INSTRUCTIONS PAGE _“_OF___2 CHANGE NOTICE ECP ENGINE OPERATING INSTRUCTIONS OICN No, F1-939 no, R-3896-11 No, ___70 a. A A lM I le A RY Before installing plug and K-seal in gas generator fuel purge ports GF2a and GF2b, visually verify that K-seal, plug, and engine port scaling surfaces are free of foreign pariicles, nicks, scratches and other imperfections that could impair sealing and that plug and engine port threads are free of damage, During installation, verify that K-seal is correctly installed on plug and centered in engine port counter- Sink before torquing plug. Two persons must inspect, and record by separate buyoff, that plug and K-seal are correctly installed, torqued, and safetywired. Record plug actual torqve value. On page 1-78E/1-78F, paragraph 1.5.1B, Special Constraints and Remarks column, opposite stepr, add constraint as follows: ~~ Before installing plug and K-seal in gas generator fuel purge ports GF2a and GF2b, visually verify that K-seal, plug, and engine port sealing surfaces are free of foreign particles. nicks, scratches, and other imperfections that could impair Sealing and that plug and engine port threads are free of damage. During installation, verify that K-seal is correctly installed on plug and centered in engine port counter- sink before torquing plug. Two persons must inspect, and record by separate buyoff, that nlug and K-seal are correctly installed, torqued, and safctywired. Record plug actual torque value. Ae ee A re oa mr ty I ee rs tema ens ap HR A} eh te wer Before installing plug and K-seal in gas generator combustor drain port, visually verify that K-seal, plug, and engine port sealing surfaces arc free of foreign particles, nicks, scratches, and other imperfections that could impair scaling and that plug and engine port threads are free of damage. During installation, verify thal K-seal is correctly installed on piug and centered in engine port counter- sink before torquing plug. Two persons must inspect, and record by seprrate buyoff, that plug and K-sea’ are correctly installed, torqued, and safetywired, Record plug actual torque value. CODE IDENT NO, 02602 DATE _3 May 1973 PAGE_3 or. 3 OPERATING INSTRUCTIONS CHANGE NOTICE NO, F1-939 NO, R-3896-11 NO..___70 On page 1-103, paragraph 1.6.7, Special Constraints and Remarks column, opposite step d, “chatigé constraint“as follows: _——- ee Before installing igniters, visually verify that seal, igniter, and cigine port sealing surfaces are free of foreign particles, nicks, scratches, and other imperfections that could impair sealing ano that igniter and engine port threads are free of damage. During installation, verify that lubrication is not used on igniter threads and that igniter seal is correcily installed on igniter and that seal seats in recessed groove of igniter port before torquing igniter. Two persons must inspect, and record by separace buyoff, that igniter and seal are correctly installed, torqued, and safety- ECP ENGINE OPERATING INSTRUCTIONS OICN | wired. Record igniter actual torque value. On page 1-104, paragraph 1, 6.10, Special constraints and Remarks ¢ _amn, opposite re a step g, add constraint as follows: Before installing hypergol cartridge, visually verify that hypergol container bore sealing surfaces are free of foreign particles, nicks, scratches, and other imperfections that could impair sealing and verify that hypergol cartridge and hypergol container threads are free of damage. Inspect hypergol cartridge exterior surfaces to verify that there are no burs or other imperfections that could damage hypergo) container sealing surfaces during hypergol cartridge installation, Two persons mast inspect, and record by separate buyoff, that hypergol cartridge is correctly installed. LL LIT Na IS TE EI FS" SPSS SS Fr aS PPP ER PME. SU rte. HIE PMOFEME TPIT ar itera MnenpaetRaattniadhiry espe, 7 a cao argc aaa aH oan oscil ie meme teaibientm, | CODE IDENT NO. 02602 DATE _1t duly 1973 PAGE or} OPERATING INSTRUCTIONS CHANGE NOTICE , | { i T* PROPOSED . F |APPROVED NO. 7) Re ree Ue ie rm tetera atten 9 anne mien ne Br INANE Pu ele mee ET. I TL SR App een 1. ECP NO. 2. ENGINE OPERATING INSTRUCTIONS 3. PAGES AFFECTED) F1-940 NO, _27-3896-11 As listed 4. EF FECTIVITY . 5. CONTRACTUAL AUTHORITY* Engines F--2029 Supplemental Agreement No. 176 to through F-2098 Contract NAS&~-25156 dated 5 July 1973 6. CHANGE This change replaces leak-test compound (MIL-L-25567) with leak-test compound (MSFC-SPEC-384) On page 2-28A/2-288, paragrayh 2.5.11, step nm, change (MJ)-L-25567) to (isre-sPRC~384) On page 2-55/2~56, paragraph 2.7.1, delete the following specification data: MI Le-25567C Leak Test Compound, 9 June 197) Oxygen Systems On page 2-55/2~56, paragraph 2.7.1, add the following specification data: USFC-SPEC—384A Leak~Test Compound, 20 December 1968 LOX Compatible This document shall be considered as a preliminary OICN until contractual coverage is received and noted in this block. OTL TN TIE O