F·l ROCKET ENGINE TECHNICAL MANUAL

publ1catton current and complete. A Change No. 12 - 12 May 19'72 PARAGRAPH TITLE R-3896-1 TABLE OF CONTENTS PARAGRAPH TITLE Contents PAGE 1 2 .1 1-2 1-1 1-~ 1-, 1-7 1-4 1-3 1-9 1-11 1-11~ 1-19 1-20 1-21 1-23 1-211 I-H) INmODUCTION F-l ~!Mit:'ALS--THEm SUPPORT FL~C TIO~S. . . . . . . . • • . . . • . . . . . . . . . •. x F-l Rocket Engine and S-IC Sta~e POsltions .................•• lX How to Ma lnta In Your Ma nual. . . . • • • xiv CO~'FIGUR.ATION ID[.\\TJFICATION...... XVl ~ID System......................... XVl Cot-.'F IGtJRATION CHANGES--MANUAL £FFEC rI\-"" I '1'Y • • • • • • • • • • • • • • • • • • • • • •• xv i S~CTION I DESCRIPTION AND oPmATION F - 1 ROCKET E~'G Th~.. .. • . • .. . • .. • .. • 1-1 F-l Rocket En~lne, Number One SIde 1-2 F-1 Rocket Engine, Number Two Side 1-3 F-1 Rocket E~ine, Forward End ...• 1-4 ENGINE PHYSICAL DESCRIPTION....... 1-1 F-1 Engine Schematic .•••••.•...••• 1-5 En~lne LeadIng Particulars (E~lnes Incorporating MD128 or ~l74 Change)..................... 1-6 E~ine Performance Schematlc (E~lnes Incorporating MD128 or !-mill Change) • . . • . • . • . • . • . . . . . . • .. l-6A PROPELLANT FEED SYSTEM DESCRIPTION 1-6B Thrust Cham~er Assembly' Del!'lcriptlon. . • • • . • . • . • • • . • . . . . . • .. l-6B Thrust Chamber Leading Particulars (E~ines Incorporating HD128 or MDlli Change). . •• •• •• . • . . •• . • •. . •• 1-8 Thrust Chamber and Nozzle Extensl.on. . • . • • . • • • . • • • • • • • . . • • . • • 1-9 Thrust Chamber Body Descript~on••. 1-8 Thrust Chamber Injector Des cr iption. • . • • • • . . • • . • • . . • . . . . • • 1-9A. Thrust Chamber Injector Compart- ment~ and Baffles..... . • • . . . • • . • • • 1-C}A. Thrust Chamber Oxidizer Dome and Manifold Descrlption.............. 1-9B Gimbal Bearing Assembly Description ..••.••..••.•••.•.. " .. 1-9B Thrust Chamber Nozzle Extens ion Description. .. . .•• . . •• . • ••• •• •• ••. '1-9B Turbopump Description •.•••..•••.•• 1-11 Turbopump Leadin" Particulars (Ln~lne9 Incorpor8tl~ HD128 or MOlli ChBn~e). . .• . . . •. . •• • . . . • . . .• I-lb 1-29 1-;2 1-35 1-:59 1-40 1-41 1-46 1-22 1-1,.9 1-51 1-53 1-55 1-57 1-59 1-61 1-63 .!.:ll 1-b5 1-67 1-68 1-69 1-70 1-71 1-73 1-75 I-j2 1-8~ 1-88 I-B9 Turbopump OXldlZer Pump Deseript ion . Turbopump Fuel Pump Descrlption . Turbopump TUrbine Descrlption . Bear ing Coo lant Contro 1 \"8 lve Description .........•............. Turbopump Fuel Inlet Elbow Dellcr iption •.......•.............. OxidIzer Valve DescrIptlon . Fuel Valv~ Descrlption .•.....••.•• Oxid~zer Valve and Fuel Valve Leading Particulars . Oxidizer High-Pressure Duct Deser ipt ion ............•.......... ~el High-Pressure Duct Des cr iptioD ••..................... Engine Interface Panel Descrlptlon IGNITION SYSTEM DESCRIPTION . HYpergol Igniter DescrlptIon . Pyrotechnlc ~nlter Descriptlon . GAS GENERATOR SYSTEM DESCRIPTIOX .. Gas GeneratDr DescrlptloD . Gas Generator Leadin~ Partlcular5 (Engines Incorporetln~ ~ID128 or MDL74 Change) . G~s Generator Ball Valve Deser Iption •...................... Gas Generator Injector O~scrlp~lon Gas Generator Combustor Deser Iptlon ••..•..•............... Gas Generator Oxidizer Duct Desar ip"tion ••.••...•...........•.. Gas Generator Fuel Duct Description ..•........•..•........ Heat Exchan«er Descrlptlon . ENG INE CONmOL SY§:TE~t DESeR IP! I ~ . Engine Control Valve Descrlptlon,. Englne Control Valve and Redundant Sbutdavn Valve Schematlc ........•. Redundant Shutdown Va h:e Deser i pt ion .••......•............. Checkout Valve D~scriptlon ,. Hyperp;ol Manifold A.ssembly Description .•...•...•............. ~ergol Manifold Leading PartIculars ••.....•.•......•...... IgnitiDn Monitor Valve DescrlptlQn I,niter Fuel Valve DescrlptIon.•.. 1- Lh I-lilA 1-17 1-17 1-21 1-21 1-21 1-::21 1-:21 1-:.n 1-23 1-2b 1-28 1-:28 1-29 1-29 1-2q 1-)0 1-,0 1- ') 1 l-V; 1-,; l-"lj 1-"l) UnderlIned numbers denote fi~ures. Underllned tItles denote primary paragraphs. Change No. 10 - 18 July 1971 Contents R-3896-1 UBLE OF CON'lWTS (continued) Underlined numbers denote fi~ure9. Underlined tl.tles denote primary paragraphs. PARAGRAPH 1-240 mANSFERROO VEHICIE 'l'o lAUNCH PAD.. ••• •••••• ••. • . .•. . •• . . . •. • . I-fll PARAGRAPH 1-71 PAGr. 1-66 1-69 1-7j 1-7'3 1-7b 1-711 1-70 1-70 1-73 1-73 1-73 1-76 1-78 I-jj 1-73 1-73 1-75 1-75 1-75 1-78 1-76 l-7b 1-76 1-7b 1-78 1-78 1-80 1-80 1-80 1-80 1-80 1-81 &HGINE FLOW AT MAl . Receiving Inspection ....•....... Engine Buildup, Modification, and Ma intenance .••..••.•.•..•... Single-Engine Checkout ......••.. Wrap-Around Duct and Hose Ins talla t ion •.•.••.•....••..••.. Engine Installation at MAr •••••• Insta lled-Engine Ins pect10n Before Stage Sh1pment to MTF .•.. Static Test Data Review ••••••••• Turbopamp Preservat10n.•..••..•. Removal af Nozzle Extensions, Slave HarcNare I and ~ITF Static Test Instrumentation ....•......• Insta lled-Eng ine lDspe ct io n Before Sta,~ Shipment to K\F .... Stage Removal From Te~t Stand ..• S'rAGE SHIP}1ENT TO M'W ...••..•... StAGE FLOW AT MTf •..••.••••.•... Stage Installation in Test Stand Engine Receiving Inspection •..•• Installation of Nozzle Exten- SlonS l Slave Hardware, and MTf Static Test Instrumentation ...•. Stage Pre-Static Checkout . Static Test •..••..•....•......•• Engine Inspection After Static Test. I .... I ••••• f ••• ,. ••••••• ,. •••• StAGE SHIPMENT 10 MAr ••••••••••• StAGE SHIPMENT TO KSC ••••.•••••• StAGE FLOW AT MAr ••••••••••••••• EngUle Recelving Inspection ...•. Engine Refurbishment ...•........ St8J1e Storage .••..•.•..••..••..• Post-Static Checkout ....•..•.... Installed-Engine Inspection Before Stage Shipment to KSC .... S~E FLOW AT KSC ..•.......••... Stage Instal1atlon Onto Launch Umbi11cal Tower (LUT) .•..••..... Engine Receiving Inspectlon •••.. Loose Equipment Installation ••.. Mod if icatioD and MB intenaDce ••.. Stage Functional Test ...•..••... Thermal InBulat~on Installation. SA'llJHN V VEHIClE FLCW AT KSC •..• Vehicle Testing •••••••••••••.••• 1-182 1-184 1-186 1-188 1-174 1-178 1-161 1-161 1-165 1-170 1-172 1-180 1-204 1-196 1-198 1-200 1-190 1-192 1-194 1-202 1-206 1-208 l-~HO 1-212 1-214 1-:210 1-218 1-220 1-222 1-224 1-226 1-228 1-2JO 1-2j2 1-2:;4 1-236 1-218 1-54 1-47 1-56 1-56 1-56 1-35 PAGE 1-40 1-40 1-42 1-43 1-38 1-39 1-63 1-45 1-45 1-45 1-45 1-47 1-47 1-51 1-47 1-64 1-64 1-64 1-64 1-64 ]-64 1-64 1-66 1-66 1-66 1-66 1-66 TITLE ENGlNE OPmATION RBJUmEHEN'l'S ••• E~ine Facility Requirements ••.• THERMAL Th"SULA.TI~ SYSTEM DESeR LPT ION ••••••••••••••••.•••• FLIGHT lNS'IRtJHmTATION SYSTEM DESCR IPTION ••••••••••••••••••••• Prlmary and Auxiliary Junction Box DescrlptioD ••••...••••••••.• Pressure Transducer Description. Temperature Transducer Description •.••.•••...•..•....•• Oxidizer Flowmeter Description •. Speed Transducer Description .••• lNGINE OPERATION •••••••••••••••• E~lne Start Sequence (Typical :5 ingle Eng~ne) ..•..•.....•..••.• E~ine Cutoff Sequence (Typical Single Engine) ..............••.. Engine Preparation Stage •••••••• Engine Start and Ignition Stage. Engine Ma iDstage •••••••••••••••• E~ine Cutoff .•••••••••.••.•••.. ENGTh'E PURGE AND DRAlN SYSTEM DESCRIPTION .•••...•••.•••••••••• Serv lCe Mode P1U',ltf' SystC'm Des cr iption •..••...••.•••••••••• Operatlonal MOde Purge System De:oocr ipt ion ••••....••.•••...••.. Service Mode Drain System Description •••••.•.•••...•..•..• Operational Mode Drain System DeecriptioD ••••••••••••••••••••• F -1 ENG Th'E FLOW' .•••.•••••••••••• ENG INE FLOW BEFORE FIELD DELIVERy •••••••••••••••••••••••• Customer Acceptance IhBppction•• Post-DD250 HainteDlDce or Mod if icat lon ••.••.••••.••••••••• ~GINE SHIPMQJT TO MAP . Preparation for Shipment ••.••••• Shipping by !ruck•.•••••••.••••• Shipping by Ship ••.••••••••••••• REX::E IV]NG ENG INE AT KU' . Receiving by rruck ••••.•••.•••.. Rece iv ing by Ship .••••.••..•••.• UNASSIGNED-ENGmE FLf)i{ AT MAF .•. Stora~e Rece lV 1.ng Inspection •••• 1-104 I-Ill 1-111 1-100 l-lO~ 1-115 1-10g 1-1VI 1-96 1-98 1-138 1-139 1-141 I-I:.!l 1-11 1-123 1-1~') 1-1~9 1-111 1-90 1-117 1-119 JclQ. 1-1/13 1-145 1-147 1-149 1-151 1-153 1-155 1-157 1-159 ii Change No. 10 - 16 July 1971 R .. 3896-1 TABLE OF CONTENTS (continued) Contents PARAGRAPH Launch Preparations and Testing. PARAGRAPH 1-2'18 1-250 1-2~2 1-2/}'1 2-2 2-', 2-1 2-6 :3-8 2-10 2-12 ~-l!1 I) - _-I 2=8 SATt~ V ~CLE LAUNCH .• _... _.. Post-Flight Data EValuation •.••• l~'~C'HEDULED MAINTENANCE FLOW' •• ,. Unschedul ed Engf ne- -Repai r and Servi cing .••.•.••••••.•••••••••• Component Repair ••.•••.••.•••••• Support Hardvare ••.•••.••••.•••• SECTION II INTERFACE DESIGN CRITFJlIA DESIGN PERFORMA.t-1CE CHARACTERISTICS ••.•.••••.••••••• R~cket Engine Ratings ••.•••••••• Rocket Engine Ratings at Standard Sea-Level Conditions •.• Nominal Altitude Performance ..•. Oxidizer Pump Cavitation •.•••••• Fuel Pump Cavitation .••••••••••• Turbopump Inlet Pressure Requirements •.••••.•.••••.•••••. Acceptable Pump Inlet Propellant Pressures for Startin~ Engine •.• Heat Exchanger Performance •.•••• Heat Exchanger F1owrates •••••.•• Helium Temperature Versus Flow and Accumulated En~ine Test Duration Curve ••.•••.••.•••••••• LOX Temperature Versue Flo~ and Accumulated Engine Test Duration Curve 41 #' ••••• Estimated Helium Inlet Temperature Transient for Heat Exchanger ••.•••••••.•••••••.•••• Estimated Helium Flowrate Transient for Heat Exchanger •••• Estimated Helium Outlet Temperature Transient for Heat Exchanger •••••••.••••••••••••••• Estimated Helium Effectiveness Versus Rplium F10wrate for Steady-State Operation of Heat Exchan~er••. _•••••••••••••• Estimated Helium Pressure Loss Versus Helium FloYTate for Steady-State Operation of Heat Exchanger .•••••.•••••••..•• Estimated Oxidizer Flowrate Transient for Heat Exchanger •••. PAGE 1-81 1-83 1-83 1-83 1-8, 1-8Z. 1-8Z. 2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-6 2-6 2-6 2-7 2-8 2-8A 2-88 2-sr 2-8E 2-16 2-10 2-18 2-19 2-21 2-23 2-27 2-29 2-11 2-31 2-3j 2-12 2-1' 2-35 2-14 2-37 :2-19 2-2OA Estimated Oxidi zer Olltl f't Temperature Transient for Heat Exchanger •..•.•.••••....... Estimated Oxidizer Outlet Temperature Versus Oxidizer Flowrate for Steady-State Operation of Heat Exchan~er..... Estimated Oxidizer Outlet Pressure Versus Oxidizer Flowrate for St~ady-State Operation of Heat Exchanger ..••• Hydraulic Control System Nominal Flow and Pressure Values •••....• Hydraulic Flowrate at ~ominal CDntrol System Values •.••••••..• ENVlRO~~AL co~~tTIO~S.•..•... Storage and Handling Temperature storage and Handlin~ Attitude •.• Standby Exposure •.....••••••...• Ground Hydraulic Fluid Supply Temperature •••••••••••••.•.••.•• Thermal Insulation Cocoon Environmental Conditioning Envelope •••••.••••••.••••.••••.• Recommtnded Thermal Insulation Cocoon Pur~e Operatin~ Ran~e Envelope •..•....•...••.•.••.•.•. MASS PROPERTIES ~TA ...••..••... Weight Status ••.••. ~ .•.•.•..•.•. Major Component W'ei~ht List ...•• Engine Weight status •••••••••••. Engine Coordinate Axes ••..••...• Coordinate Axis Diagram .••.••••• Center of Gravitv and Inertia Data. It ••••••• II •• L III •• Weight, Center ot Gravity, Moment of lner~ia, and Product of Inertia Data (Engines F-202~ Through P-2042) •••.•.•..•..•.••• Weight, Center 01 Gnl\-i t~· i Moment of Inertia. and Product of Inertia Data (En~neg F-204) Throu~h F-206j) ••.•..••.•.••.•.• Wei~ht1 Center Qf GraVity, Moment of Inertia, and Product of Inertia Data (En~ine! F-~o66 Through F-2(89) •••••.••..••••..• Weight, Center of Gravit., Moment of In~rtia, and P;'oduct of Inertia Data (En~ines F-:JOlt 5-1 and F-2090 Thro ll~h F-2098) ••..•.•..•••..•.•..•••••• 2-8K 2-8L 2-6 2-9 2-6 2-6 2-6 2-6 2-9 2-10 2-10 2-10 2-10 2-10 2-11 2-11 ~-12 2-1::' :::!-l"i :3-1; Un,Iprli ned numht"TS denote fi ~res. Undprlined titles denote primary paragraphs. Change No. 9 - 4 November 1970 iii Contents R ... 3896-1 TABLE OF CONTmTS (continu@d) PARAGRAPH PARAGRAPH ;-j 3-6.A - 1)- l-_ 1 "')-y ;-1 3-1 1-10 i-10 1-10 '1-10 "1-17 ')-1<1 ;-20 1-21 3-22 Sea-Level Characteristlc Veloclty Versus Thrust at Nomlnal Mixture Ratio and Temperature (En~lne~ Incorporat~ng MD128 or MOlli Change) ..•...•................... Sea-Level Thrust BDd Thrust Coefficient Versu8 Chamber Pres- sure at Nom~nal Mixture Ratio and Temperature (Engines Not Incor- porating MD128 or ~lli Change) •• Sea-Level Thrust and Thrust CoeffIcient Versus Chamber Pres- sure at Nominal Mixture Ratio and Temperature (Engines Incorpo- rating MDllB.or MDlliChange) •..• Nominal Thrust Chamber Performance Values ..••..••.••.... Nominal Turbopump Performance Va lues •••.•••.•••.•••.•.•.••...•. Oxidizer Pump Developed Head Versus Volumetric Flowrate . Fuel PUmp Developed Head Versus Volumetrlc Flowrste ••..••.•...•.. NomiDal Gas Generator PerfOrlll8DCe Va lues .••..•...•..... Nominal Heat Exchanger Performance Values .•............. En~ine Start Character18tlcs ..... NomlDal Valve Openlng Times f01' Mainstage ...•.•.......•..•....... Nominal Thrust BUIldUp and Approximate Propellant Con- 8umptloD Values for MalDstage ..•. Nominal Start Times From Engine Control Valve Open SignaL .•••... Engine Schematic !Pre-start) •.... En,ine Schematic I~nitiQn) . Engine Schematlc ~~lnstage)..•.. Eng iDe Dra in and Pur ge Schema t ic . Engine Stop Characteristics ..••.. NomiD81 Cutoff Times From Englne Control Valve Stop Si,rnal. ••..••. NomiDBl Thrust Decay TIme From Engine Control Va Ive Clos iIll! Signal ..•••..••..••...•...••..... Nominal Thrust Decay and Cutoff Ilipulse ••••.•••.•••..••••••..••.. MEnlODS Felt FRED IC TING ENG WE VARIABLE CHARACTDUSTICS . EDgine Start Tlme Predictions (Referenced to E~ine Control Valve Openin~ Si~nal and Based on Sta~e Appllcation) ...•...•...• FUel Pump Impeller Backcasln~ Pressure He-Or if ic iOI[ Techn lqU P •• ;-12 3-8 3-1lt 1-~1 3-20 3-22 "5-4 3-5 ;-1 3-3 3-3 3-4 3-2 1-2 3-1 2-70 2-38 2-54 2-54 2-55 2-54 2-55 2-51 2-55 2-55 2-56 2-56 2-56 2-36 2-57 2-15 2-14 2-23 2-14 PAGE 2-14 2-14 TITLE SH::TION III PERFORMANCE Nominal Thrust Buildup Characteristics •••••.••••••••••• Gimbal Buildup Characteristics •. Gimbal Supply Pressure V~r8u8 Sea-Level ThMlst •..•.•..•••••••• Nominal Thrust Decay Characteristics .•••••••••••••••• Nominal Gimbal Supply Pres8ure Decrease Characteristics •••••••• Sea-Level Specific Impulse VersuB Thrust at Nominal Mixture Ratio and Temperature ••• Sea-Level Characteristic Velocity Versus Thrust at NomiDal Mixture Ratio and Temperature (En~iDes Not Incor- poratln~ MDI~S or MOlli Cha~e). NO~NAL PERFORMANCE CHARACTERISTI CS ••••••..••••••••• Nominal En~ine-Performance Values 41 . JOINT AND SEAL DATA •••••••••.•.• Seal Description •••••••.•••.•••• Seal Application (Typical) •••••• Naflex Seals •.•••.••••••••.•••.• Gask -O-Sea,l s ••.••••••.•.•.••.... K-Seala ••••••••••••.••••.••••••. O-Rin~ Seale ••••.••••••.•••••.•• Asbestos S@als ••.••.••.••••••••• Copper Crush Seals •..•••••.••••• Flared Seals ••......•.••••.•.••• Spiral-Wound Gaskets and Metal O-Rinlls ••...••••••••.•••••••.••. Joint and Seal Identification.•. Svstem Joint and Seal Schematic. P~rge and Drain Joint and Seal Schematic ....•••.•.••••.••.••.•• I~~ERFACE CONNECTIONS ••••..•.••• Interface Connect Points •..••••• Operating and Servicing Interface Connections •..•.••..•. Envelope Dimensions ••..•.•.••••. Engine Envelope Dimensions •••••• Electrical Interface •••••••.•••. Electrical Interface Requi rements ••••.••••••.•••••••• Instrumentation Tap Locations and Identification •.•••••••••.•• Instrumentation Tap Locations .•• Tap Code Identification System •• Accelerometer Code Identification System••••••••••• "5-5 1-2 1-2 3-4 3-8 2-2'1 2_'.8 2_1,9 2-61 2-26 2-27 1-1 o ;-6 2-10 2-51 2-25 ~ --) ) 2-~4 2-55 2-56 2-57 2-58 2-jQ 2-60 2-47 2-lt1 2-22 2-4'> I') 1')- :.==2 2-")Q 2-~1 2-21 Underlined numbers denote fi~lres. Underlined titles denote primary paragraphs. iv Change No. 10 - 16 July 1971 R-3896-1 TAB I}: Of COliT!':\n; (continued) Contents PARAGRAPH TITLE PAGE PAllAGllAPH TITU, j'.\(il - O' )-- ( )-28 Re-Orificlng With No Change In Fuel Pump Oper8ti~ ConditIons .. 3-25 Re-Orlficlog WIth Changes In Fuel Pump Inlet CondItions...... 3-~5 Re-Orificing With Changes ID iUrbopulDp Speed................. 3-25 ;-',8 EC'iGI)lE TeST PISTRP[f:\'TATIO'l 1_116 EnjIine Instrumentation Paramet~rs ••••••••••.••..••••.•• APPENDIX MANUAL DATA SUPPLDolENTS .. A-I 3-31 )-38 3-40 3-40 3-42 3-43A ;_41A 3-46 IlEAT EXC HANG Ell 'PmFORMANCE EVALUATION AND PREDICTIQN ...•..• Heat Exchanger Computer Program Options , . Heat Exchanger Performance EvaluDtion Bnd Predic~iOD Input Data Requirements . ENGINE INFUJENCE COEFFICIENTS ... RP-l Fuel Density Versus Tempera ture . OXIdizer Density Versus Tempera ture . Calculations involvIng 8 Typical Engine . Calculations Involving B Spec if 10 Engine . Test trend Corrections . Turbine Nozzle Area Change Versus Burn Time (Engines F-2029 Through F-2065 •••••••••• Turbine Efficiency Ratio Curve Change Versus Burn Time (Engines F-2029 Through F-2065) •••••••••• Thrust Trend for Flight (Engine8 F-2029 Through F-2065) ••••••••• Nonlinear Corrections •••••..•.• C~ Correction Curve (Actual) (Engine. F-2029 Through F-2065). Turbine Nozzle Area Change Versus Burn Time (Engines F-2066 and Subsequent) ••••••••• Turbine Efficiency Ratio Curve Change Versu8 Burn Time (Engines F-2066 and Subsequent) ••••••••• Thrust Trend for Flight Engines (EnKines F-2066 and Sublequent). c* Correction Curve (Actual) (Enginee F-2066 and Subsequent). Component Replacement Effects on Engine Performance at Sea Level ••••••••.••••••.•••••••••• Example of Calculations Required to Determine Deviations in Englne Performance Due to Component Replacement •••...• ;-25 ;-27 3-26 3-39 3-42 3-42 ;-41 3-41 ;-41 ;-44 ;-44 ;-4'-A 3-43 3-4'-A 3-44C 3-44C 3-44D 3- 1,5 ;-4; 3-46 Underlined numbers denote figures. Underlined tltles denote primary paragraphs. Change No. 12 - 12 May 1972 v Illustrations R-3896-1 LIST OF ILLUSlRATIONS FIGURE FIGL1lE 1 -; " 1-1 I " -- 1-1 1-', I-I) I-",A I-b 1-7 [-8 1-9 1-10 1-11 l-l~ I-I; 1-14 1-15 1-16 1-17 1-18 1-19 1-20 [-21 1-22 1-23 1-24 l-25 1-26 1-27 1-28 1-29 1-30 F-l llock(lot Engine nnd S-IC Stag@ Po:- itionEl . 110"'· to Malntain Your Manua l. . MD System ........•.•............• Configuration Changes--Manual Effeetivity . F-l Rocket En~lne, Number One ~ Ide . F-l Rocket Englne, Number Two Slue ........... ..............•... F-l Rock~t En~inp, Forward End ... F-I Engine Schematic .........•... En~lne Leading Particulars (Engines Incorporating toID128 or MDlli Ch.nge) ••.•..•...•..••••.•. Enp;ine Perfarruance Schematic (EngInes Incorporating MDl,g], or MDlli Change) •...••......•...•... Thrust Chamber Assembly ..••..•... Tlu-ust Chamber Leading Par- tlculars (EngInes Incorporating MDI:l8 or MDI,', Change): .........• Thrust Chamber and Nozzl~ Extenslon ....................•... Thrust Chamber Injector Compartments and Baffles .....•... Thrust Chamber OXIdizer Dome .•... Glmbal Bearin,g: ...............•... Thrust Chamber Nozzle Extension .. Turbopump (Inbo.rd) .•...•..•••••• Turbopump (OUtbo.rd) .......•.•... Turbopump Cutaway . Turbo pump Leading Particulars {Engines Incorporat.ing MD128 or MDlli Change) .••.••••.•••..•.•.•• OxidIzer Pump and Fuel Pump ..•.•. OXIdizer Pump and Fuel Pump BearIngs ........•.•..........••.. Fue 1 Pump and Turb lne •....•..•.•. Bearing Coolant Control Valve . OxIdizer Valve . Oxidizer Valve and Fuel Valve Leading Part.iculars ..........•... Fuel Valve ...................•... Engine Interface Panel . Hypergol Igniter . Pyrotechnic Igniter . Gas Generator Leadlng Particulars (EngInes Incorporating MD128 or MDl2i Change) .•.•..••.••.~•..•• Gas Generator . Gas Generator Ba 11 Va Ive .. " . Gas Generator Injector and Combustor . ix xiv xvi xvii l-:l 1-3 1-4 1-5 1-6 l-bA 1-7 1-8 1-9 1-91\ 1-10 1-11 1-12 1-13 1-14 1-15 1-16 1-168 1-168 1-18 1-18 1-20 1-21 1-22 1-23 1-2!t 1-24 1-25 1-26 1-27 1-28 1-31 1-12 1-33 1-34 1-;5 1-36 1-37 1-38 1-39 1-40 1-41 1-42 1-'.3 1-44 1-45 1-46 1-47 1-47A 1-48 1-49 I-50 I-51 1-52 . 1-53 1-5_ I-55 1-56 I-57 I-58 1-59 1-60 1-61 1-62 1-63 1-64 1-65 1-66 1-67 1-68 Heat Exchanger . Engine Control Valve and Redundant Shutdown Valve Schematic . Redundant Shutdown Valve . Checkout Va lve . Hypergol Manifold . Hypergol Manifold Leoding Particulars . Ignition Monitor Valve . Flight lnstrumentatl.Q.n System Parameters •....................... Primary Junction Box •....•.....••. Auxiliary Junction Box . Pressure Transducer . Temperature Transducers . Oxidizer Flowmeter . Speed Transducer . Engine Thermal Insulation . Engine Purge and Drain SchematIc .• Engine Fuel and Control Fluid Overboard Drain Schematic (Engines Not Incorpor.ting MDlli Challlle) ..• Engine Fuel and Control FlUid Overboard Drain Schematic (Engines Inoorpor.tillll IIIlli Change) .....•. Fuel Drain Manifold .. Engine Purge and Oxidizer Over- board Drain Schematic . Engine Facility Requirements . Engine Start Sequence {Typical Single Engine) .•....•...••..•..... Engine Cutoff Sequence (Typical Single Engine) ....•••...••..••..•• Engine Preparation Comple~e (TYPic.1 Single Engine) •.••.•..... Eogine Ignition Stage ...•..•...... Engine MB iDstage ...........•...... Engine Cutoff . Engine Start Sequence Flow (TYPical) .•.••.••.••.•••.....•.••• Engine Cutoff Sequence Flow (TYPicol). ' •...•••..•.••..••.••... F-l Engine Flow . Engine Shipment to MAP . Receiving Engine at MAP . Engine Flow at MAF . Engine lnsta llation at MAP . Stage Shipment to MTF •...••.••.... Stage Flow .t MTF .••••..••.••.•... Stage Flow .t MAF .••...•••..••.... Stage Flow .t KSC .•••...•..••••.•• Saturn V Vehicle Flow at KSC . PAGE 1-29 1-31 1-34 1-34 1-36 1-37 1-37 1-38 1-39 1-39 1-40 1-41 1-42 1-43 1-44 1-46 1-48 1-4&\ 1-49 I-50 I-51 I-52 I-54 I-55 I-57 I-58 1-60 1-61 1-62 1-63 1-65 1-67 1-68 1-71 1-72 1-74 1-77 1-79 l-~ vi Change No. 10 - 16 July 1971 R-3896-1 LIST OF ILLUS1RATIO~S (contll'med) Illustrations FIGURE 2-1 2-5 2-& ~-7 ~-8 2-9 2-9A 2-9B 2-<JC 2-9D 2-9E ~-9F 2-9G ~-9H 2-9J 2-9K 2-9L 2-9M 2-10 2-11 ~-12 2-11 2-1.!t Rocket Englne Ratings at Standard ~ca-Lcve1 Co nd 1 tlO OS •••• (Deleted) Nominal Altitude Performance .•..• OxldlZer Pump Cavitation Characteristics ...........•.•• ~ •• Fuel PulllP CavltatLon Characteristics , ..•..••...• Acceptable Pump Inlet Propellant Pressures for Starting Engine .•.. Heat Exchanger Flovrates .•.....•. Hellum Temperature Versu8 Flow and Accumulated Eng ine Test Duration Curve ••••••.••••••..•••. LOX Temperature Versus Flow BDd Accumulated Engine Test Duration Curve .••••••••••....•.••••..•••.• Estimated Helium Inlet tempera- ture Transient for Heat Exchanger Estlmated Helium Flovrate Tran5lent for Heat Exchanger ..... (Deleted) Estlmated Helium Outlet Tempt>r8- 'ture 'l'ransunt for Heat Exchanger (Deleted) Estimated Hellum Effectlvene~s Versus Hellum Flo~ate for Steady-State Operatlon of Heat F.JI::changer . (Deleted) Estimated Bellum Pressure Loss Versus Hellum FloWT8te for Steady-State Operatlon of Heat Exchanger •••......•.•...••.. EstImated Oxidizer F10vrate Transient for Heat Exchanger .••.• Estimated Oxidizer Outlet Temperature Translent for Heat Exchaager ....•.•...•.•••.••• Estilll8ted Oxidizer Outlet Temperature Ver8u8 OXIdizer F10WTate for Steady-St.ate Operation of Heat Exchanger .•.••. Esti;aated Oxidizer Outlet Pre8sure Versus Oxidizer F1uvrate for Steady-State Operation of Heat Exchanger .•..•• Hydraulic F10wrate at Nominal Control System Values ••••.•••.••• Recommended Thermal Insulatlon Cocoon Purge Operatlng Range Enve lope •......• ' •...••.••....•.. MaJor Component W~ lll!:ht List ..•... En~ln~ Wel~ht Status •..•......... Coordlnate AXls Dla~ram.........• PAGE 2-1 2-3 2-4 2-5 2-6 2-6 2-7 2-8 2-SA 2-8B 2-SC 2-BD 2-SE 2-SJ 2-BK 2-8L 2-8M 2-9 2-10 :2-10 :2-11 :.!-l~ 2-15 2-16 2-17 2-18 2-19 2-20 2-20A 2-21 2-22 2-23 2-21t 2-25 2-26 2~27 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 '-ll TITLE 1 Del.ted) Del.ted) De leted) Welght, Center of GraVity, X()l!lent of Inertia t and Product of Inertla Data (Engines F-~029 Through F-2042) ......•...•................ WeIght, Center of GraVity, Moment of Inertla, and Product of Inertla Dota (Engines F-20"3 Through F-2065) ......•.....•.............. We ight, Center 0 f Gra"·l ty I Home ot of Inertia, and Product of IDertI8 Dota (Engines F-2066 Through F-2089) . Weight, Center of Gravity, Mriment or Inertia, and Product of Inertla Data (Engines F-20"5-1 and F-209O Through F-209S) . Operating and ServlciDg Interface Connect ions .•...••.•••..•......... Englne Envelope DlmemuoDs . Electrical Interface Requirements. InstrulIIentatlon Ta p Loca tlODS •.... Seal Application (Typical) ..•..... System JOlnt and Seal Scbematlc ... Purge and Dra in Jo lnt a cd Sea 1 Schematic .....•........•...•....•. Nomlnal Engine Performance Values at Sea Level and Standard Turbo- pump Inlet Conditl.oDs ••.......... , Nominal 'l'hrust Buildup Character lstic8 •.•..••...•....•... Gimbal BuildUp Cbllracteristlcs ...• Gimbal Supply Pressure Versus Sea-1e'Ve 1 Thrust ...•....•.••...... NOlllinal Thrust Decay Character ist ics. , •...••.•••..•.. , , No~inal Gimbal Supply Pressure ~crease Characteristics ..•....... (Deleted) Sea-Level Specific Impulse Versus Thrust at Nomlnal Mixture ~atlo and Temperature ...•.....•......... (De Ie ted ) Sea-Level Cbar8cteristlc Veloclt;r Versus Thru~t at Nomlnal Mlxture Ratio and Temperature (Engines Not IncorporatIng MD128 or MDli.r. Change) .••.......••..••..... " ..• , Sea~Level Cbaracterlstlc Veloclty Versus Thrust at Nomlnal Mlxture RstlQ and Temperature (Eo,lnes IncoqlQr8tln~ ~lln2B or MD174 Chana e ) ....•..••..•............... PAGE 2-12 ~-ll 2-13 2-14 2-15 2-21 .2-~q 2-~7 2-55 o -- .. -J I ~-70 ]-L 3-2 J-2 3-3 3-3 3-4 3-4 3-5 )-j Change No. 10 - 16 July 1971 vii LIST OF ILLUSTRATIONS (continued) F IGIIII.E 3-12 1-12A 3-13 1-15 3-16 3-17 3-18 3-19 3-20 3-21 3-22 3-22A 3-23 3-24 3-25 3-26 3-27 1-28 3-28A 3-29 1-30 3-Jl 3-32 1-33 3-34 3-35 3-36 3-37 3-38 Sea-Level Thrust and Thrust Coe f( ic ient Versus ChBtIlber Pressure at Nominal Mixture Ratio Bnd Temperature (E""ines Not Incorporating MDl~8 or MDlZi Chan~e) .......•.......•..•.....•. Sea-Level Thrust and Thrust Coefficient Versus Ch8~ber Pres- sure at Nominal Mixtur~ Ratio and Temperature (Engines Incorporatl"l MDl28 or MDlli Chonge) .. Nominal Thrust Cha~ber Per forma nee Values ....•......•••• Nominal Turbopump Performance Va lues ..• , •...••.•••.••.••••••.•. (Deloted) Oxiduer Pump Developed Head Versus Volumetric Flowrate ....•.• (Deleted) Fuel Pump Dneloped !-read Versus Volume tric Flowrate •.....•••..••• NomlDal Gas Generator Performance Values .•..••..••.•.••.• , .••.•••.• Nominal Heat Exchanger Perf armance Va lues ••... , •.••..•• , Nomina 1 Va lve Opening Times for MIl ina1:.age .••..••••...••.•...•...• Nominsl Thrust Buildup Bnd Approximate Propellant Consump- tion Values for MBinstage •.•.•••. NomInal Start Times From Engine Control Valve Open Signal. ••..... Engine Schematic lPre-start) ....• Engine SchematiC Ignition) •...•. Engine Schematic Ma IDst8ge) ..••. Englne Drain and Purge Sche..tlc. Nominal Cutoff Times From ECline Control Valve Stop Signlll. •••..•• Nominal Thrust Decay Time From EOIiDe Control Valve Closing SignaL . Nominal Thrust Decay and Cutoff Impulse . Heat Exchanger PerformaDce Evaluation and Prediction Input Data Requirements .•••..••.••..••• Deletedl Deleted Deleted De leted) Deloted) Deleted) Deleted) De le ted) Deleted) PAGE 3-6 1-liA 3-7 3-7 3-8 3-9 3-9 3-9 3-10 3-10 3-10 3-17 3-19 3-20 3-21 3-22 3-22 3-22 3-26 FIGlIlE 3-39 1-U 3-4lA 3-41C ;_42 3-43 3-44 ;-4" ;-45 3-46 TITLE Engine Influence Coefficients (Predicted) (Engine. F-2029 Through F-2065) . RP-l Fuel Deosity Versus Temperature •••••••••••••••••••••• Oxidizer Density Versus Temperature •••••••••••••••••••••• Turbine Nozzle Area Change Versus Burn TiMe (Engine. F-2029 Through F-2065) ., •••••••••.•••••••••••••• Turbine Efficiency Ratio Curve Change Versus Burn Time (Engines F-2029 Through F_2056) ••.•••.•••. Thrust Trend for Flight (Engines F-2029 Through F_2065) .••••••••.• C* Correction Curve (Actual) (Engines F-2029 Through F-2065) Engine Influence Coefficients (Predicted) (Engine. F_2066 ond Sublequent) •••••••••••••••••••••• Turbine Nozzle Area Change Versus SUm Tise (Engine. 7-2066 ond SUbsequent) •••••••••••••••••••••• Turbine Efficiency Ratio Curve Cbange Versus Burn Time (Engines F-2066 ond Subs .quent) .. Thrust Trend for Flight Engines (Engines F-2066 ond Sub.equent) ., C· Correction Curve (Actual) (Engine. F_2066 ond Subsequent) ., Example of Calculations Required to Determine Deviations in Engine Performance Due to Component Replacement •••••••••.•••••••••••• Engine Instrumentation Parameters. PAGE 1_41, 3-44C 3-440 J-4'j ;-!16 "5-5'5 viii Change No. 12 - 12 May 1972 R-3896-1 , ~ ..... . ...-~ Figure lA. F-l Rocket Engine (Typical Flight Configuration) Change No. 6 - 14 August 1968 In troduc Han viiiA/viiiB R-3896-1 INTRODUCTION Introduction This manual is one of seven R-3896-series technical manuals prepared to provide official Rocketdyne field support documentation for the operation and maintenance of the F-1 Rocket Engine, Part Number 104001, Serial Numbers F-2029 through F-2098, and Its related ground support equipment, designed and manufactured by Rocketdyne, a division of North American Rockwell Corporation, 6633 Canoga Avenue, Canoga Park, California 91304. The informa- tion in these manuals was prepared by Logistics Publlcations & Training Department of Rocketdyne. This manual contains engineering data detailing engine operation and engine system functions. For stage design criteria, refer to F-l Engine Interface Document R-6749. Five F-l rocket engines are installed on the S-IC stage. Figure 1 shows engine positions relative to stage positions and fin locations. The instructions In the manuals are used more effectively when each manual is current and complete (see figure 2) and the purpose and scope of each manual is known. The manuals that complete this series, and the nature of the data each provides, are found in the manuals contents and support functiona chart. FIN B PIN A VUW LOOKING .FORWARD P06:rrION """" PIN D FIN C PIN C Figure 1. F -1 Rocket Engine and S-IC Stage Positions Change No.9 - 4 November 1970 ix Introduction R-3896-1 1. F-l MANUALS--THEm SUPPORT FUNCTIONS. The contents and support function chart lists all F-I-series technical manuals, describes the support function each manual serves, and lists the section titles of each manual. The chart also explains how the technical data in each manual relates to the support of the engine and its ground support equipment throughout a normal engine flow, as well as during unsched- uled maintenance tasks. Information appearing in one manual Is not duplicated in another. Thus, information On the description, opera- tion, and maintenance of ground support equip- ment Is in R-3896-5. However, the Instructions for servicing the engine using ground support equipment are in R-3896-3 and R-3896-11. Manual I R-3896-1 F-I Rocket Engine Data Contents and Support Function This manual contains a physical description of the various F-I engine systems and the individual engine system components, a de- scription of the now the engine follows from the time it is accepted by the Customer through Apollo! Saturn V launch; data pertaining to engine design characteristics in- cluding environmental conditions, attitude, mass properties data, turbopump inlet propellant con- ditions, and interface connections for mating the engine with the S-IC of the Saturn V vehicle; and nom- inal engine performance charac- teristics, methods for predicting engine variable characteristics, and other pertinent information that can be used as an aid [or ana- lyzing and/or determining specific engine performance. The manual serves to familiarize the reader with the design and operation of the F -1 engine and serves as a training aid document. Section and Title See detailed table of contents for this manual. R-3896-3, Volume I F-I Rocket Engine Maintenance and Repair This manual contains general main- I tenance practices that are peculiar to the engine covered in this volume II and to the component repair proce- 1Il dures contained in Volume II of this manual; the use of engine, thrust IV chamber, and nozzle extension ground support equipment and the taaks necessary to prepare the equipment for maintenance using the appllcable pieces of ground sup- port equipment; detailed procedures for component removal, reinstalla- tion, Or replacement; and the post- installatton test requirements that will verily the integrity of engine systems affected by the removal of individual engine components and General Maintenance and Repair Handling Component RemOVal and Installation Post-Maintenance Test Requirements x Change No. 10 - 16 July 1971 I II ill IV V VI VII VIII IX X XI XII xm XIV XV XVA XVI xvn XVIn XIX XX XXI XXII xxm XXIV Manual R-3896-3, Volume I (cant) R-3896-3, Volume II F-l Rocket Engine Maintenance and Repair R-3896-1 Contents and Support Function lines. This volume and Volume II provide the necessary maintenance and repair data to perform Wlsched- uled maintenance tasks on an unin- stalled engine and the required post- maintenance tests to determine that the engine is in an operable condition. This manual contains cleaning, in- specting, repairing J and testing procedures for the individual engine components. This manual provides the data to restore and/or maintain components of the engine in an oper- able condition for reinstallation on the engine or assignment as a spare. Introduction Section and Title Quick-Disconnect Gas Generator Gas Generator Ball Valve Gas Generator Inj ector Purge and Pump Seal Purge Check Valve Deleted Heat Exchanger Heat Exchanger Check Valve Thrust Chamber (Installed) Thrust Chamber (Uninstalled) Thrust OK Pressure Switch Inert Prefill Check Valve Oxidizer Dome Purge Check Valve Oxidizer Valve Fuel Valve Turbopump Turbine Bearing Coolant Control Valve Deleted Electrical Harness Hypergol Manifold Ignition Monitor Valve Checkout Valve Engine Control Valve Four- Way Solenoid Valve Thrust Chamber Nozzle Extension XXV Pressure Transducer XXVI Temperature Transducer XXVII Flight Instrumentation Junction Boxes XXVIII Rigid Ducts, Flexible Lines J and Braided Flex Hoses XXIX Redundant Shutdown Valve XXX Volumetric Liquid Oxygen Transducer (Oxidizer Flowmeter) XXXI Gimbal Boot, Insulation Boot, and Insulation Seal Change No. 11 - 10 November 1971 xi Introduction Manual R-3896-4 F -1 Rocket Engine Illustra ted Parts Breakdown R-3896-5, Volume I F -1 Rocket Engine G round Support Equipment Mainte- nance and Operation R-3896-1 Contents and Support Function This manual contains illustrative and columnar listings of all parts of the engine that can be disassem- bled, reassembled, repaired, re- placed, or overhauled. This manual locates and identifies the interrelationship of parts, aids in the requisition of replacement parts, and indicates part usage and interchangeability and recommended repair or replacement for the F-l engine and its individual components and parts. This manual contains safety re- quirements and general maintenance practices peculiar to the equipment covered in this volume and to equip- ment and T-tools covered in Vol- ume II of this manual and includes inspection requirements, physical description, operation, intended usage, operating limitations, periodic maintenance, and parts listings with maintenance-level codes for the F -1 engine gro-.md support equipment covered in this volume. This volume provides data to restore and/or maintain the F -1 rocket engine ground support equipment in an operable condition. I II III I II III IV V VI VII VIII IX X Xl XII Xln XIV xv Section and Title Introduction Group Assembly Parts List Numerical Index Safety Requirements, General Maintenance, and Handling and Shipping Equip- ment Hydraulic Pumping Unit G2025 Hydraulic Pumping Unit G2026 Accumulator Unit G2027 Engine Checkout Console G3142 Pneumatic Flow Monitors G3130 and 03131 Engine Vertical Installer 04049 Engine Rotating Sling G4050 Flight Combustion Momtor 703227 Components Test Console G3141 and Components Adapter Set 03143 Cryogenic Supply Unit G3146 Pneumatic Flow Testers 03104 and G3104MDI High- Voltage Igniter Tester G3153 and Inert Igniter 9026622 Impact Recorder Unit G4090 and 99-9014031 Components Welding Sets 9026560, 9026561, and 9026570 xiI Change No.7 - 18 August 1969 Manual R-3896-5, Volume II F -1 Rocket Engine Ground Support Equipment Mainte- nance and Operation R-3896-6 F-1 Rocket Engine Thermal lnsulatlon lnstallatlon and Repair R-3896-9 F -1 Rocket Engine Transportation R-3896-11 F -1 Rocket Engine Operating Instructions R-3896-1 Contents and Support Function This manual contains inspection I requirements, physical descrip- II tion, operation, intended usage, ill operating limitations, periodic maintenance, and parts listing with maintenance-level codes for the F -1 engine ground support equipment end items !hat are con- sidered tools (ie, test kits, sets, and tools) and T-tools. This volume provides data necessary to determine that those items of ground support equipment covered by this volume and the F-l field T-tools are in an operable condi- tion. This manual contains a description I of the thermal insulation panels, II special tools and equipment, in- ill stallation and removal procedures, access provisions, repair data, and applicable packaging, storage, IV and handling information. This manual provides information per- tinent to the maintenance and V repair of F-1 engine thermal VI insulation. VII This manual contains procedures I for preparing the F-l rocket engine, II nozzle extension, thermal insulation, ill and miscellaneous engine loose equip- IV ment for shipment, and procedures for shipping by truck, air, or water. Included are recommended truck-, air-, and water-transport checklists, which may be used to make sure that procedures and in-transit inspection have been performed. This manual contains complete, I authorized field operating require- II ments !hat affect F-1 flight engines III F-2029 through F-2098 during nor- mal operational flow from engine receipt at MAF through vehicle launch. Specific and general require- ments and procedures for normal F-1 engine activities are pro~ided and include acceptability criteria and limits, special constraints, safety precautions, and correct sequences required to satisfactorily accomplish the activities Introduction Section and Title Test Kits, Sets, and Tools T-Tools Dummy Weight T-Tools Description Special Tools and EqUipment Installation and Removal (Engines F-2003 Through F-2016) Installation and Removal (Engines F-2017 and Subsequent) Access Provisions Repair Storage and Handling Preparation for Shipping Shipping by Truck Transport StJpping by Air Transport Shipping by Water Transport Operating Requirements General Requirements Operating Proce:lures Change No. 12 - 12 May 1972 xiii Introduction R-3896-1 USE YOUR MANUAL ONLY IF CURRENT AND COMPLETE Manuals that are not current and complete are not authoritative documents and are not to be used. The following outlines the method for determining whether your manual is cur- rent and complete. A. DETERMINING CURRENCY. To be sure that yours is the latest issue of the manual, refer to Configuration Identification & Status Report ,which is revised monthly and lists the technical manual numbers, titles, unin- corporated supplements, and latest change or revision dates. Your manual must have a title page with the same or later date than the date shown in the Configuration Identifi- cation & Status Report. Your manual must also include the unincorporated supplements listed in the Configuration Identification & Status Report, or if your manual is later than shown In the report, the unincorporated sup- plements listed in the Manual Data Supple- ment Record in your manual. if your title page incorporates two dates as illustrated be- low. compare the change (lower) date. if your manual Is not current, obtain a current copy through your technical manual supply system. .. _- listed with their Issue dates, Manual pages that are dated must have the same date as that appearing in the List of Effective Pages for that page. Unchanged pages are listed as "original" and are not dated. HOW TO KEEP YOUR MANUAL UP-TO-DATE As design changes are made to the rocket en- gine and ground support equipment and better methods of maintenance are discovered, your manual is periodically changed. reVised, or supplemented. The following steps will help you keep your manual up-to-date: A. CHANGES. Updating by adding to or par- tially replacing existing pages is defined as a change. Changes can be identified by the change notice on the new title page. To collate a change, refer to the Filing Instruc- tions sheet issued with the manual and proceed as follows: I~ "JUIY~].JI~l"~ 1. Remove the pages listed in the "Remove" column of the Filing Instructions sheet from the manual and destroy them. Do not concern yourself with the data on the opposite side of the deleted page since, if this date is not deleted, it is replaced in the change package. B. DETERMINING COMPLETENESS. To be sure that your manual is complete, make a page-by-page comparison of its pages to those listed In the List of Effective Pages. The List of Elfective Pages, which shows the change status since the baSIC issue or last revision, is round on the alphabetically let- tered page(s) Immediately follOWing the title page, AJI pages. except suppJenlents. are 2. Insert all pages listed in the "Insert" column of the Filing Instructions sheet in sequence. Pages with a suffix letter are inserted in alphabetical order follow- Ingthe page with the same basic number: for example, pages 3-14A, 3-14B, etc, follow page 3-14. GEN-NASA-1A Figure 2. How to Maintain Your Manual (Sheet 1 of 2) xi,' Chanl4e No. 11 - 10 Novemher 1971 R-3896-I Introduction 3. If you are unsure of the status of any page or pages, refer to the List of Effec- tive Pages and make sure your manual contains pages (with the corresponding change dates)listed in the List of Effec- tive Pages. 4. Remove manual supplements that have been incorporated. NOTE Incorporated supplements can be determined by reviewing the newly issued Manual Data Supplement Record. B. R EVlSIONS. Updating by replaCing all the existing pages of a manual is defined as a revision. Revisions can be identified by the replacement notice on the new title page. 1-'''''- - . ..... Till' PUBLICATION 1U::!'LAC~s T~CIINICAL MA.'~AL R-XXXX-X DATeD 1 Al~llL 19b9 To collate a revision. proceed as follows: 1. Remove and destroy all existing pages of your manual except Manual Data Supple- ments that have not been incorporated. NOTE Unincorporated supptements can be identified by reviewing the Manual Data Supplement Record supplied in the reVision. 2. .Insert the new pages in your cover. C. SUPPLEMENTS. Updating that author- izes the addition to, or alteration of, the ex- isting data in your manual is defined as a Manual Data Supplement. Information on how to insert supplements is found in the supple- ments. HOW TO KEEP ABREAST OF THE LATEST CHANGES TO TECHNICAL DATA Changes and/or additions to technical data are identified by a vertical bar (change bar) in the margin of the page adjacent to the changed data. A direct comparison between the new (identified by the change bar) and the old data will help you in identifying specIfic changes made. GEN-NASA-2 Figure 2. How to Maintain Your Manual (Sheet 2 of 2) Change No. 7 - 18 August 1969 xv Introduction R-3896-1 MDl.! NOT INCORPORATED MOll AND MDU,.INCORPORATED MDl THROUGH MD9 INCORPORATED MDllNCORPORA TED IN PRODUCTION ~ :BY KIT MDlQ NOT lNCOFtI'ORA TED 7 MD IDENTIFICATION ~ ,I P 2' P , P ~ P ~ P • P 1 P 8 P 9 K 10 II K 12 I( 13 I" I( 15 I( 16 K 17 II I( 19 20 21 22 2.3 2.4 2~ 26 21 2. 2. 30 JI 32 13 34 !lS 3. n !. 3' 40 41 42 43 44 4~ 46 47 48 ~ ~ lSI S2 S3 !Soli ~!5 ~IIS !S7 51 n eo 61 62 63 14 85 66 67 • 6i 70 11 72 73 74 75 7. 77 71 '7' eo 81 82 83 84 85 86 87 88 89 90 91 92 13 94 9!l 96 97 9. 99 100 RD171-1052-0001 PLATE [R Ir-- DE _N_ T ----, GE:N-71 to the equipment covered in this manual are listed in figure 4. The date in the last column is the pUblication date of the manual during which the change made by the ECP was incorpo- rated. When NI A is entered, the ECP does not change the data in the manual. Engine configu- ration information is in R- 5857, Saturn F-l Configuration Identification & Status Report. Engine serial numbers within this manual are in accordance with Rocketdyne F-l engine desig- nation. For F-l engine serial number allocation, refer to the cross ... reference index in R- 5857. 2. CONFIGURATION IDENTIFICATIDN, EQUIPMENT CONFIGURATION. The MD identification symbol and the equipment model designation indicate the configuration of the equipment and distinguish it from models in- corporating different changes and from basic models. A basic, unchanged configuration of the equipment has no MD identification symboL MD identification sumbols are added as changes affecting configuration are incorporated into the equipment. The MD identification symbol is stamped on the MD plate, which is mounted near the engine nameplate. MD IDENTIFICATION SYMBOLS. On MD iden- tification plate RD171-1022-0001, the identifica- tion symbol Is a composite number representing all the changes affecting configuration (MD changes) incorporated or not incorporated into the equipment. The symbol represents a con- secutively numbered series of MD changes. Any MD change, or series of MD challfies, not incorporated is represented by an "X. t MUlti- digit numbers are underlined. Two figures to- gether represent the limits of a series of incor- porated MD changes. Figure 3 illustrates how MD changes incorporated in the engine are represented by the MD identification symbol. MD identification plates RD171-1052-0001 through - 0006 have preprinted numbers from 1 through 100 on the -0001 plate, 101 through 200 on the - 0002 plate, et c. Modifications that are incorpo- rated into the equipment are represented by the letter P (production) or K (kit) stamped in the square directly to the right of the applicable number. Omission of a P or K, indicates that the MD cha~e is not incorporated. A P or K with a bar (-) marked through the letter (~,Jr) indicates a MD change deleted in its entirety by the incorporation of a later MD change. Figure 3 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; for example, "MD9" refers to MDt through MD9, but "MOO change" refers to the individual MD change 9. This latter type of reference, which is illustrated in figure 3, identifies separate sets of information required by differences in configuration. When an MD reference appears in this manual, examine the MD identification symbol on the equipment to determine which set of information is applicable. 3. CONFIGURATION CHANGES ... -MANUAL EFFECTIVITY. All approved ECPs (Engineering Change Pro- posals) and associated MD numbers applicable Figure 3. MD System xvi Change No. 12 - 12 May 1972 R-3896-1 Introduction Approved incorporated in Approved incorporated in ECP No. MD No. Manual Dated ECPNo. MDNo. Manual Dated Fl-38 37 17 May 1965 Fl-174 21 N!A Fl-38Rl N/A Fl-174Rl N!A Fl-39 11 8 June 1964 Fl-176 22 N!A Fl-40 N/A (superseded Fl-180 34 27 October 1964 by Fl-254) Fl-182 7" N!A Fl-42 7 8 June 1964 Fl-185 32 11 May 1964 Fl-45 7 8 June 1964 Fl-185Rl N!A Fl-56 7 8 June 1964 Fl-188 7 27 October 1964 Fl-57 7 8 June 1964 Fl-188Rl N!A Fl-59 7 8 June 1964 Fl-189 7 27 October 1964 Fl-60 16 N/A Fl-191 7 27 October 1964 Fl-62 7" 8 June 1964 Fl-192 46 28 September 1965 Fl-64 7 N/A Fl-192Rl N!A Fl-65 7 8 June 1964 Fl-192R2 N!A Fl-67 10 8 June 1964 Fl-193 7 27 October 1964 Fl-69 T 8 June 1964 Fl-193Rl N/A Fl-71 9 8 June 1964 Fl-194 7 27 October 1964 Fl-74 7 8 June 1964 Fl-195 7 27 October 1964 Fl-76 24 27 October 1964 Fl-196 29 N/A Fl-76Rl N/A Fl-197 W 27 October 1964 Fl-78 7 8 June 1964 Fl-198 26 N/A Fl-80 7 8 June 1964 Fl-198Rl N!A Fl-82 18 8 June 1964 Fl-202 7 27 October 1964 Fl-85 T 8 June 1964 Fl-206 22,66 27 October 1964 Fl-86 7 8 June 1964 Fl-206Rl N/A Fl-90 7 8 June 1964 Fl-206R2 N/A Fl-91 7 N!A Fl-208 33 27 October 1964 Fl-95 7 8 June 1964 Fl-214 TI 28 September 1965 Fl-97 7 8 June 1964 Fl-214Rl N/A Fl-98 20 N/ A (superseded Fl-215 116 8 August 1966 by Fl-197) Fl-215Rl N/A Fl-99 14 8 June 1964 Fl-215R2 N/A FI-I00 7" 8 June 1964 Fl-216 31 N!A FI-I0l 8 8 June 1964 F1-216Rl N!A F1-106 7 8 June 1964 F1-217 7 N/A FI-108 7 8 June 1964 F1-226 35 N!A F1-124 7 8 June 1964 F1-228 36 27 October 1964 F1-129 8 N/A F1-229 T 27 October 1964 F1-129R1 N/A F1-229R1 N/A F1-131 7 N/A F1-233 38 28 September 1964 F1-132 7 8 June 1964 F1-235 3I N!A F1-135 7 8 June 1964 F1-236 T 27 October 1964 Fl-143 11 8 June 1964 F1-241 7 27 October 1964 Fl-143R1 N/A F1-242 39 27 October 1964 F1-146 1 8 June 1964 Fl-244 T 27 October 1964 F1-147 7 8 June 1964 Fl-251 7 27 October 1964 Fl-149 11 27 October 1964 F1-253 43 N/A Fl-153 T N/A Fl-254 T 27 October 1964 Fl-154 7 8 June 1964 Fl-255 42,45 N/A Fl-166 13 8 June 1964 Fl-258 22 27 October 1964 Fl-168 T 8 June 1964 Fl-258Rl N/A Fl-169 7 8 June 1964 Fl-258R2 N/A Fl-172 7 8 June 1964 Fl-260 54 N/A Figure 4. Configuration Changes--ManuaI Effectivity (Sheet 1 of 4) Change No. 7 - 18 August 1969 xvii Introduction R-3896-1 Approved Incorporated in Approved Incorporated in ECP No. MDNo. Manual Dated ECP No. MDNo. Manual Dated Fl-260R1 N/A Fl-313 69 28 September 1965 Fl-260R2 155 N/A Fl-313R1 N/A Fl-261 22 17 May 1965 Fl-314 31 28 September 1965 Fl-262 "50 N/A Fl-315 70,83 28 September 1965 Fl-263 TI N/A Fl-315Rl N/A Fl-267 49 17 May 1965 Fl-315R2 N/A Fl-268 "59 17 May 1965 Fl-316 31 8 August 1966 Fl-268R1 N/A Fl-317 'IT 8 August 1966 Fl-269 55 17 May 1965 Fl-319 31 N/A Fl-270 4'1" 28 September 1965 Fl-320 '7'! 8 August 1966 Fl-270R1 N/A Fl-320R1 N/A Fl-270R2 N/A Fl-321 31 28 September 1965 Fl-274 53 N/A Fl-323 84,"8'!, 86 N/A Fl-276 22 N/A Fl-323R1 N,/A Fl-277 n N/A Fl-323R2 N/A Fl-278 R N/A Fl-323R3 N/A Fl-279 II N/A Fl-324 72 28 September 1965 Fl-279R1 N/A Fl-324R1 N/A Fl-282 31 12 January 1966 Fl-326 79,80,95 N/A Fl-283 3 14 October 1966 Fl-328 -'71l- 28 September 1965 Fl-283Rl N/A Fl-328R1 N/A Fl-283R2 N/A Fl-331 31 8 August 1966 Fl-285 68 28 September 1965 Fl-332 n N/A Fl-285R1 N/A Fl-333 '54 8 August 1966 Fl-287 31 14 October 1966 Fl-335 31 31 March 1967 Fl-288 3I 14 October 1966 Fl-342 30 N/A Fl-289 n N/A Fl-343 90,91 31 March 1967 Fl-289R1 N/A Fl-347 31 31 March 1967 Fl-289R2 N/A Fl-352 3I 12 January 1966 Fl-294 57 17 May 1965 Fl-352Rl N/A Fl-294Rl N/A F1·353 82 N/A Fl-294R2 N/A Fl-356 88,93 28 September 1965 Fl-303 54 8 August 1966 Fl-357 89 8 AU!JUst 1966 Fl-303R1 N/A Fl-358 n 8 August 1966 Fl-304 67 N/A F1·360 99 8 August 1966 Fl-304R1 N/A Fl-361 n N/A Fl-305 73 28 September 1965 Fl-362 '54 31 March 1967 F1·305R1 N/A Fl-369 94 8 August 1966 FI-306 66 N/A F1·370 ~ N/A Fl-306R1 N/A Fl-370R1 N/A Fl-306R2 N/A Fl-370R2 N/A Fl· 307 74 N/A Fl-370R3 N/A Fl-307R1 N/A Fl-370R4 N/A Fl-308 31 N/A F1·371 31 7 April 1966 Fl-309 77,'Sii,95 8 August 1966 Fl-372 ~ 31 March 1967 Fl-310 '18',"80,95 8 August 1966 Fl-372R1 N/A Fl-311 31-;1'08 28 September 1965 Fl-372R2 N!A Fl-311R1 N/A F1·378 58 N/A Fl-312 96,97 12 January 1966 F1·378R1 N/A Fl-312R1 N/A F1·378R2 N/A Fl-312R2 N/A Fl-378R3 N/A Fl-312R3 N/A Fl-379 101 12 January 1966 Fl-312R4 179 N/A Fl·379R1 N/A Figure 4. Configuration Changes--Manual Effectivity (Sheet 2 of 4) xviii Change No. 9 - 4 November 1970 R-3896-1 Tnlr<Jdurti I if. Approved Incorporated in Approved Incorporated In ECP No. MDNo. Manual Dated ECP No. MD No. Manual Dated Fl-379R2 N/A Fl-436 123 8 August 1966 Fl-380 99 7 April 1966 Fl-437 115 14 October 1966 Fl-381 3I N/A Fl-437R1 N/A Fl-391 102,103 7 April 1966 Fl-437R2 N/A Fl-391R1 N/A Fl-437R3 N A Fl-392 137 31 March 1967 Fl-438 131 31 March 1967 Fl-392R1 N/A Fl-439 146 10 August 1967 Fl-392R2 N/A Fl-439R1 N/A Fl-405 128 31 March 1967 Fl-441 140 10 August 1967 Fl-405R1 N/A Fl-441R1 N/A Fl-405R2 N/A Fl-441R2 N/A Fl-406 31 March 1967 Fl-441R3 N'A Fl-407 109 31 March 1967 Fl-443 129 14 October 1966 Fl-407R1 N/A Fl-444 ill 10 August 1967 Fl-408 104 7 April 1966 Fl-444R1 N/A Fl-408R1 7 April 1966 Fl-444R2 N/A Fl-409 105 7 April 1966 Fl-445 122 8 August 1966 Fl-410 m 31 March 1967 Fl-445R1 N/A Fl-410R1 N/A Fl-447 138 N/A Fl-415 107 8 August 1966 Fl-447R1 N/A Fl-416 120 31 March 1967 Fl-447R2 N/A Fl-416R1 N/A Fl-448 149 10 August 1967 Fl-417 N/A Fl-448R1 N/A Fl-418 31 March 1967 Fl-448R2 N/A Fl-418R1 N/A Fl-449 127 31 March 1967 Fl-419 31 March 1967 Fl-449R1 N/A Fl-419R1 N/A Fl-452 12t3 31 March 1967 Fl-420 31 March 1967 Fl-452R1 N'A Fl-420R1 N/A Fl-453 123 N A Fl-421 N/A Fl-454 118 31 March 1967 Fl-421R1 N/A Fl-454R1 N/A Fl-421R2 N/A Fl-454R2 N/A Fl-422 113, 114 8 August 1966 Fl-456 124 8 August 1966 Fl-422R1 N/A Fl-456R1 N/A Fl-423 119 N/A Fl-457 136 N'A Fl-423R1 N/A Fl-459 no 31 March 1967 Fl-424 110 8 August 1966 Fl-464 14 October 1966 Fl-424R1 N/A Fl-467 N/A Fl-426 117 8 August 1966 Fl-467R1 N/A Fl-426R1 N/A Fl-468 128 31 March 1967 Fl-427 111 31 March 1967 Fl-470 140 10 August 1967 Fl-427R1 N/A Fl-470R1 N/A Fl-427R2 N/A Fl-470R2 N/A Fl-428 87 N/A Fl-471 N/A Fl-428R1 N/A Fl-475 N'A Fl-430 112 8 August 1966 Fl-475R1 N/A Fl-431 137 31 March 1967 Fl-475R2 N/A Fl-431R1 N/A Fl-476 135 31 March 1967 Fl-431R2 N/A Fl-476R1 N/A Fl-432 125 31 March 1967 Fl-478 137 N/A Fl-432R1 N/A Fl-478Rl N/A Fl-432R2 N/A Fl-478R2 N/A Fl-434 121 31 March 1967 Fl-480 132 31 March 1967 Fl-434R1 N/A Figure 4. Configuration Changes--Manua1 Effectivity (Sheet 3 of 4) Change No. 10 - 16 July 1971 xix Introduction R-3896-1 Approved Incorporated in Approved Incorporated in ECP No. MDNo. Manual Dated ECP No. MDNo. Manual Dated Fl-480R1 N/A Fl-535 N/A Fl-482 133,134,142 31 March 1967 Fl-543 165 11 March 1968 Fl-482R1 -142- 10 August 1967 Fl-543R1 N/A Fl-495 144 10 August 1967 Fl-545 154 11 March 1968 Fl-495R1 N/A Fl-547 169" N/A Fl-498 145 10 August 1967 Fl-548 160 13 February 1968 Fl-498R1 N/A Fl-548R1 N/A Fl-498R2 N/A Fl-552 1'70 14 July 1968 Fl-499 137 10 August 1967 Fl-552R1 N/A Fl-499R1 N/A Fl-552R2 N/A Fl-500 150,151 10 August 1967 Fl-579 11 March 1968 Fl-500R1 N/A Fl-580 N/A Fl-502 148 N/A Fl-581 167,168 14 July 1968 Fl-504 m 31 March 1967 Fl-581R1 N/A Fl-504R1 m 10 August 1967 Fl-581R2 N/A Fl-505 161 N/A Fl-581R3 N/A Fl-505R1 N/A Fl-581R4 N/A Fl-505R2 N/A Fl-586 N/A Fl-506 159 13 February 1968 Fl-587 N/A Fl-507 N/A Fl-590 176 18 August 1969 Fl-509 143 N/A Fl-590R1 N/A Fl-510 152 10 August 1967 Fl-590R2 N/A Fl-510Rl N/A Fl-590R3 N/A Fl-511 146 10 August 1967 Fl-590R4 N/A Fl-511R1 N/A Fl-591 172 N/A Fl-512 177 10 August 1967 Fl-592 173 18 August 1969 Fl-512R1 N/A Fl-592R1 N/A Fl-515 147 14 July 1968 Fl-594 N/A Fl-515R1 N/A Fl-594R1 N/A Fl-521 154 13 February 1968 Fl-596 174 N/A Fl-521R1 N/A Fl-596R1 N/A Fl-521R2 154 11 March 1968 Fl-597 175 N/A Fl-521R3 N/A Fl-801 N/A Fl-521R4 183 N/A Fl-602 178 N/A Fl-522 N/A Fl-604 180 4 November 1970 Fl-523 13 February 1968 Fl-807 181 4 November 1970 Fl-524 13 February 1968 Fl-607R1 N/A Fl- 525 157,158 13 February 1968 Fl-607R2 N/A F1- 525R1 N/A Fl-607R3 N/A F1- 526 156 14 July 1968 Fl-612 184,185 4 November 1970 Fl-526Rl N/A Fl-612R1 N/A Fl-530 162,163 13 February 1968 Fl-612R2 N/A Fl-530R1 N/A Fl-613 ~,187 4 November 1970 Fl-530R2 N/A Fl-617 N/A Fl-530R3 N/A Fl-618 188, 189, 190 N/A Fl-618R1 N/A Figure 4. Configuration Changes--Manua1 Effectivity (Sheet 4 of 4) xx Change No. 12 - 12 May 1972 R-3896-1 SECTION I DESCRIPTION AND OPERATION Section I Paragraphs 1-1 to 1-8 1-1. SCOPE. This section contains a general description of the F-1 propulsion system and a detailed description of each subsystem and com- ponent. Engine operation from the preparation phase through and including the engine cutoff phase is defined. Also included, are external inputs necessary for engine operation, typical engine operating parameters, and a description of the flow the engine follows from the time it is accepted by the Customer through Apollo! Saturn V launch. 1-2. F-l ROCKET ENGINE. 1-3. The F-l propulsion system was developed to provide the power for the booster night phase of the Saturn V vehicle. Five engines are clustered in the S-lC stage of the Saturn V to obtain the necessary 7,610,000 pounds thrust. 1-4. The engine features a two-piece thrust chamber that is tubular-walled and regenera- tively cooled to the 10:1 expansion ratio plane, and double-walled and turbine gas cooled to the 16:1 expansion ratio plane; a thrust chamber mounted turbopump that has two centrifugal pumps spline-connected on a single shaft driven by a two-stage, direct-driven turbine; one-piece rigid propellant ducts that are used in pairs to direct the fuel and oxidizer to the thrust cham- ber; and a hypergolic fluid cartridge that is used for thrust chamber ignition. 1- 5. The engine is within an envelope of approxi- Imately 12.5 feet in diameter and 19.2 feet long and weighs approximately 18,600 pounds dry. Refer to section II for specific dimensions and weight. Thrust vector changes are achieved by gimbaling the entire engine. The gimbal block is located on the thrust chamber dome, and actuator attach points are provided by two out- riggers On the thrust chamber bOdy. 1-6. Component locations on the engine in the horizontal position are basically referenced to No. 1 (left) (figure 1-1) or No. 2 (right) (figure 1-2) sides ot the engine as viewed trom the exit end of the thrust chamber with the turbopump at ,12 0' clock (top) and the hypergol manifold assembly at 6 0' clock (bottom). Component locations on the engine in the vertical position are referenced to the principal component on the four sides of the engine (eg, gas generator side (No.1), engine control valve side (No.2), turbopump side, and hypergal manifold side). A view of the forward end of the engine is shown in figure 1-3. 1-7. ENGINE PHYSICAL DESCRIPTION. 1-8. The F-1 engine is a Single-start, fixed- thrust, liquid bipropellant engine, calibrated to develop a sea-Ievel-rated thrust of 1,522,000 pounds with a specific impulse (lsp) of 265.3 seconds. Engine propellants are liquid oxygen and propellant kerosene fuel at a mixture ratio of 2.27:1. The propellant kerosene fuel is used as the working fluid for the gimbal actuators and for the engine control system and is also used as the turbopump bearing lubricant. The F-l engine is comprised of seven operational systems: (1) A propellant feed system, which sup- plies pressurized propellants for combustion and hydraulic pressure fur the engine control system. (2) An ignition system, which initiates combustion in the gas generator and the thrust chamber. (3) A gas generating system, which pro- duces the energy to drive the turbopump and condition propellant tank pressurants. (4) An engine control system, which regu- lates the start, operating level, and shutdown of the engine. (5) A flight instrumentation system, which measures selected engine parameters for moni- toring and evaluating the operational characteris- tics of the engine. (6) An environmental conditioning system, which protects the engine from extreme tempera- ture environment caused by plume radiation and backflow during night. (7) A purge and drain system, which in- hibits contamination and facilitates the overboard disposition of expended fluids. Detailed infor- mation of the engine system and its components is in the following paragraphs. An engine fluid Ischematic (figure 1-4), engine leading particulars (figure 1-5), and an engine performance sche- matic (figure 1- 5A) are inclUded to support the text. Detailed information On engine operation is presented in paragraphs 1-121 through 1-133. Change No. 10 - 16 July 1971 1-1 ::1 (") fz ? ID I ... Z ~ ~ ~ ...ID cg iNTERFACE I'AN"L.~ ':", .. "'UAP-AROUND tiNES AND DUCrS NO. J OXWJ2f"U lOGH-PUESSUIIE DUCT TIIERMAL INt>ULA110N BUACKET,S NO. I fUEL INLET ELBOW GAS GENERATOR BALL VALVE NO. I FU[I, HIGH PRESSURE DUCT ~ x- ~~~~~ /' j 4)7 .....~;,- , MANIFOL.D , ,"' . \ ~ ~ ~ " ~. } OVER80ARD DnAlN LINES en..n :t. § - ::0I ~ '"'", ... FI I :IliA Figure 1-1. F-l Rocket Engine, Number One Side Figure 1-2. F-1 Rocket Engine, Number Two Side , .... ~ • '" <Xl '" <Xl I ... CIl ..o a:o " to'I-I-39A NO. 2" QXmrZI':R VAl-VI': TVR80PUMP Cltf.CKOIJT VAI.V,.: r THL """" IN::,V LA nON BltACKET'5 NO 2 tv..:1. VALVE NO.2 FUEL JNU.T £1.BOw I' ENGIN": 1:1»•..1"1'1101 \'1\ LV 1-:----- "·UU.OVEHUOAHI) liUAIN UNF NO 2 FUEL lUGH- PRESSURE DUCT -- THRllST CHAMBER NOZZLE EXn:NSION\ [I l ""..z0 • 1 "\ '\. ".,.. \ ~ ., '"I .... Z ~..B '" l!l I THllU:>T CUAMOt:n .... '" -'I 0 ....I '" Section I R-3896-1 I GOX RETt."RN HELH:M SUPPLY • ~l~TERFACE ./' PANEL Tt:RBQPl"MP FUEL INLET NO, 1 ~, .... HYDRAULIC RETURN TURBOPUMP OXIDIZER INLET I • TURBOPUMP FUEL INLET NO.2 HYDRAULIC SUPPLY TlJRBOPUMP OXl:D1ZER SEAL PURGE cocoor-;" __-;'''--';Cil~:PURGE :. THRCST CHAMBER JACKET PREFILL Figure 1-3. F-1 Rocket Engine, Forward End 1-4 Change No. 9 - 4 November 1970 Figure 1-4. F -1 Engine Schematic ~ IGJ<IT'.. ~'GRlTE.. g> n ~ o "- ::0, '"'" '" 0> , ... Fl-'-41 '0 '0 '0 ~::E 'ff~:;SYll~':":U:U~(C~;;~;::;;::;~TU~R~IlO~P~U~"~PII~~r~~,~ F'-:";::;~OOXIDI:E:==== I rom~' ~ ~ -"'-1 -- -fj: PUn~LIl 1I(X)(.'QQJi1 - U SUPPLy PURGE II l.....!i G¥URft,YLlCU SUPPLY U UPURGI; I~F====I] ~ Ei;:"P lffifi ~ R ~ r,:::~l1~~=~~~~~lo.~f'~~ II~~ Pi T':':ST ( ~ '-Z' ~\.l:lTa Du D~~~~~UT CIiAII...... ~ U ~ m'L ~ n' ~ Irrl '::.~~a~"lb fi"] r"fJ Isu- ~~,.J,[ 11Jll..... '. fill ]I==! III '''LYE -I' I:Id IXj ~~TOOII~L _ .U- t' -~ c;/ u= P .TART In G.tlI O.....1OR - - - =- '~ II" I II Q"BAL~~ CONTROLYALVB~ ~ HUT AC1VATOftS II ~ 11 EJ:CItANGER Lt 4:)rI r= n ----. ~ C'.... Q'- ~"C ] U ~ U ~~ DfCBE = ~ (X)HTftOL I F V BYPEROOLII ~'=AL="===>1~ FLOWIOiTEII Ir ill (~r;===r=il~GS' PIIUS,I'I = ---, I <CJ ,........,0;1.._ rr== '~ 0 n ~ , U ~ == :A : =j1c:l=~=:1----. NO ,"" U~ U......I«), I ~iaoii.J I I 1Ir ,-- I "'''''''':~.., .ALYrau J1 ~ n ~;~~L m~.c:: I~ IT 1J ~ UI':fYE ~ ,C~ ""l!-wl U U .-J",,}U C I,...rl): ...... , puk PU'L pc:- e-iriC b~;" II ~ TBRU5T 11 YAL:i LL<:ht=]"........ I w II C......." oo0סס0 lb 0 _ f--o l I _PURGE_ -> - , U! ... '" ... '" 0> '" jtil ~ i'"~ Section I R-3896-1 "hrust level (sea level) 1,522,000Ib Gas generator mixture 0.416: 1 ratio Specific impulse (sea level) 265.3 sec Gas generator combustor 980 psia pressure I ToW,,,,,,,,,,,, n_." 5,737lb/sec Gas generator temperature 1,453· F (40,670 gpm) Fuel 1,756 lb/sec Turbine speed 5,492 rpm (15,632 gpm) Time from turbopump 5.2 sec Oxidizer 3,981lb/sec Initiation to rated speed (25,038 gpm) Time from cutoff 3.5 sec to zero rpm Mixture ratio 2.27:1 Expansion ratio 16:1 Turbine brake horsepower 53,146 hp Thrust chamber pressure 1,125 psla Nozzle extension coolant 1,138·F Thrust chamber 5,970' F gas temperature temperature Hydraulic recirculation 11.6 ±l. 1 gpm Thrust chamber exit 9.6 paia flowrate at 1,500 psig pressure (16:1) Engine dry weight 18,619 lb Fuel pump discharge 1,870 psla (average) pressure Oxidizer pump discharge 1,602 psia pressure Gas generator flowrate 167 lb/sec (included In total) Fuel 118 lb/sec Oxidizer 49lb/sec • Figure 1-5. Engine Leading Particulars (Engines Incorporating MD128 or MD174 Change) 1-6 Change No. 10 - 16 JUly 1971 :0I ...'" <0 '"•.... l,941.0 tD ~u: - ------ 118.0 LA/SEC IJ-1 _ 1.052 IN 86.0 PSIO (ACTUALI n. 'I LIl'SEC FLOW t.O LII'SEC ( l.9116.0 tB,SEC 6'i 0 I':>IA ISTA(jNATIONJ 8'lB II Ltl/SEC Q 0'~45 « PSlA IST"hNATIONI -- _::..::J ---------- 1 996 0 to 's-tee .s:60LO PSI'" (STALNATIONJ II M V U.O LB/SIEC ~) (i; 1 l):;JO.I6(jU\l. II .....,sUJ-[C I ~I D"it:... &4S.0 PSIA ISTAGNATION) 1.560.0~ r 911C1.O PSIA- ISTA~ATI()fIl) 878. 0 U~ $f"C -I5apSIA-~ ISTAGNATlO,'Il ~ '0 ----,,~.~.~..~.~.~L~"CCSE< B1,603.0 PSIA -;-z I 1STMiNATJON''t-}_'- -'=~ ); ~~ z ? ....o ..... '" '-< " .:;; ....<0 -.1 .... 1,820.0 PSI" 1ST.,,:o"ATION) J . .831 IN. 181 0 ":ill) lACTUAL! J all IN 157.0 PSID lAC'rUAL/ • 0 IN o 0 PSlD - g> "::r. g H I In Figure 1-5A. Engine Performance Schematic (Engines Incorporallng MD128 or MD174 Change) I .... -----~_ .. , ~ Section r Paragraphs 1~9 to 1-13 .-9. PROPELLANT FEED SYSTEM DESCRIPTION. R-3896-1 1-10. The propellant feed system transfers oxidizer and fuel, under pressure, from the propellant tanks to the thrust chamber and gas generator. The system consists of the following major components: A thrust chamber, a turbopump, two oxidizer valves, two fuel valves, two high-pressure oxidizer ducts, two high-pressure fuel ducts, and two fuel inlet elbows. 1-11. THRUST CHAMBER ASSEMBLY DESCRIPTION. 1-12. The thrust chamber assembly (figure 1-6) is the engine section within which the engine thrust Is developed and by which this thrust is transmitted to the thrust structure of the booster stage or test stand. The thrust is developed through the process of burning propellants in the combustion chamber and accelerating, to supersonic velocity, the gaseous products of this combustion through an expansion nozzle. The thrust is transmitted through a gimbal bearing and two gimbal actuator outrigger assemblies. 1-13. TI,e thrust chamber assembly consists of a two-piece thrust chamber, an injector, an oxidizer dome and manifold, and a gimbal assembly. The gimbal assembly attaches to the oxidizer dome by eight bolts. The oxidizer dome is boIted to the Injector by 16 Inner-dome support bolts, and both the oxidizer dome and injector are bolted to the thrust chamber body by 64 outer-dome attach bolts. The dome, in- jector, and thrust chamber body are Indexed to each other by one diamond- shaped and one round, noninterchangeable Index pin, spaced 180 degrees apart at the Interface flanges below the two oxidizer dome Inlets. The mating flanges of the dome and injector are sealed by a Teflon-filled Flexitallic gasket. The mating flanges of the injector and thrust chamber body are sealed at the outer diameter by a Vlton-A O-ring and at the Inner diameter by a hollow Inconel-X O-ring. The Inconel-X a-ring in- corporates drllled holes In its outer diameter to permit injector manifold fuel pressure to enter the hollow section to Increase Its sealing I capability. Thrust chamber leading particulars are presented in figure 1-7. Thrust chamber and nozzle extension are Illustrated in figure 1-8. 1-6B Change No. 10 - 16 July 1971 OUTER DOME ---- ATUCH BOLTS NO. 1 OXIDIZER INLET-- J SEAL NO.1 FUEL "'LET ----'"""7..:::;;..:::~ GIMBAL OUTRlOCiERS (2) DRAIN ADAPTERS (4) R-3896-1 Section GIMBAL BEARING .__------NO. Z OXIDIZER ~. INLET t..:...... OXlDIZER DOME ___-FLEXlTALLlC GASKET • ------THRUST CHAMBER ~ INJECTOR t'"",,-----_TOPS MOUNnNG PADS TURBOPUMP SUPPORT OUTRIGGERS (21 TURBlNE EXHAUST """"FOLD Figure 1-6. Thrust Chamber Assembly Change No. 7 - 18 August 1969 1-7 Section I Paragraphs 1-14 to 1-16 U"ust level (sea level) .vlixture ratio Propellant flowrates Oxidizer Fuel Inj ector end pressure Fuel injector manifold pressure Exit pressure (16:1) Combustion area temperature Nozzle extension coolant gas temperature Fuel inlet manifold pressure 1,522,000Ib 2.40:1 3,933lb/sec 1,636 lb/sec 1,125 psla 1,222 psia 9.6 psia 5,970' F 1,138' F 1,466 psia R-3896-l Oxidizer dome pressure dl-op Fuel jacket pressure drop Valves pressure dl-ops Oxidizer Fuel Expansion ratios Thrust chamber Thrust chamber and nozzle extension Fuel jacket prefill Solution C1pacity 57 psla 244 psia 91 psia 210 psia 10:1 16:1 Ethylene glycol 103-105 gal. Injector pressure dl-ops Oxidizer 309 psia Fuel 97 psia I Figure 1-7. Thrust Chamber Leading Particulars (Engines Incorporating MD128 or MD174 Change) 1-14. THRUST CHAMBER BODY DESCRIP- TION. The thrust chamber body contains a combustion chamber for the burning of the pro- pellants, and a nozzle of the required 10: 1 elt- pansion ratio for expelling gases produced by the burned propellants at the supersonic velocity necessary to produce the desired thrust. 1-15. The thrust chamber body is a furnace- brazed, tubular-walled, regeneratively fuel- cooled, bell-shaped chamber Incorporating two outrigger arms to support the turbopump and two outrigger arms to which the gimbal actua- tors attach. A fuel inlet manifold and a turbine exhaust manifold are welded to opposite ends of the chamber. One hundred seventy-eight pri- mary tubes, hydraUlically formed from 1-3/32 inch outside diameter Inconel-X tubing, make up the chamber body above the 3: 1 expansion ratio plane (approximately 30 inches beloW the throat centerline plane). Three hundred fifty- six one-inch-outside-dlameter secondary tubes of the same material form the chamber from the 3: 1 to the 10: 1 expansion ratio plane. A raised weld bead with the tube number and a directional flow arrow, identify fuel-up tube No.1 and fuel-down tubes No. 60 and 120 on the chamber internal faces of the injector end ring 1- 8 , Change No. 10 - 16 July 1971 and fuel return manifold. External to the cllam- ber the same tubes are similarly identified on reinforcing bands and straps below the thrust chamber throat. 1-16. Two secondary tubes are brazed to each primary tube at the 3: 1 expansion ratio area plane. Every other primary tube Is a fuel-down tube and is slotted on its outboard side at the fuel inlet manifold area into which fuel from the inlet manifold is directed. An oriflced plug is brazed into the tube above the slot to permit 30 percent of the fuel to go directly to the fuel in- Jector manifold. The remaining 70 percent of the fuel is used for regeneratively cooling the thrust chamber and Is directed down the tube to the fuel return manifold at the end of the cham- ber. From the fuel return manifold, the fuel is directed by the adjacent fuel return tubes to the fuel injector manifold. The return manifold is welded to the bottom of the thrust chamber secondary tubes and incorporates four drain ports, located 90 degrees apart, to drain re- sidual fluids. Forty lugs are welded to the inside _11 of the return manifold for attaching the turbine exhaust leak- test fixture. R-3896-1 Section I 401 .. ,~ l" 'oj \" ' ,:\~,,. ~I l·'.:~r XOZZLE TADPOLE SEAL EXTE:-SJ01\ iASBESTOSI FLA:-OCE EXHAUST GAS FLOW , TENSION TIE f"UEL DOWN TUBEJ4 Ft'EL RETURN TL:BE HOT GAS-...... '~' FLAME SHIELD ~ " \:.... FUEL RETURNMANIFOLD THRUST CH .... M 8tR NOZZLE EXTENSION CON:-;EC'f FLANGE ADAPTER • RADIAL EXPANSION JO,,"rS,....:.....:::..__~~rt GlMBAL OUTRIGGER .....----ARMj\ Brn'RCATION JOINT ,'3 1 EXP A.NSION PLANE \ r1-1-43.~ Figure 1-8. Thrust Chamber and Nozzle Extension Change No.8 - 19 February 1970 1-9 Section I P!1ragraphs 1-17 to 1-19 R-3896-1 4-17. The fuel inlet manifold, welded to the upper end of the chamber body, incorporates two flanges, 180 degrees apart, for mOWlting the main fuel valves. A three-section flange for mOWlting the thrust OK pressure sWitches, and another for attaching the prefill check valve, are located on the inlet manifold. The fuel in- let manifold distributes fuel from the main fuel valves to the thrust chamber fuel-down tubes through angled, radial passages drilled through the inner wall of the manifold and alined with slots in the primary fuel-down tubes. rings, orificed-drilled to provide a doublet oxidizer-on-oxidizer impingement, are brazed to the oxidizer ring grooves. The twelve radial. fuel-cooled, copper baffles are supplied with fuel by the outer circular baffle to which they are brazed. Two igniter fuel housings in each of the 12 outer compartments and one igniter fuel housing in the center compartment, connected by individual fuel feed tubes to the igniter manifold, inject igniter fuel to the compartments. The center of compartment No. 13 is threaded for the attachment of the throat plug shaft. Figure 1-9. Thrust Chamber Injector Compartments and Baffles NOTE lNJEC'1'OR COMPARTMENTS ARE INDlCATEO SY NUMBERS 1 tHROUGH 13. BAFFLES ARE INDICATED BY LETTERS .A THROUGH N. 1-18. The turbine exhaust manifold collects and evenly distributes the turbine exhaust gas to the area between the walls of the nozzle ex- tension. The exhaust manifold is a CRES torus of decreasing (from inlet to exit) cross- sectional area incorporating 15 omega expansion joints to compensate for thermal growth. Splitter plates at the inlet and flow vanes at the exit area contribute to the uniform distribution of the exhaust gases into the nozzle extension. The exhaust manifold is welded to a flame shield that is welded to the outer wall of the thrust chamber. 1-19. THRUST CHAMBER INJECTOR DE- SCRIPTION. The thrust chamber injector dis- tributes the propellants into the combustion chamber at the proper mixture ratio, pressure, and spray pattern to initiate and sustain stable combustion. It is aCRES, 31-ring, plate-type injector, divided into 13 compartments by 2 circular and 12 radial baffles, which dampen tangential and transverse combustion instability shock waves generated during combustion. The compartments are identified numerically, 1 through 13, and the baffles alphabetically, A through N. (See figure 1-9.) The 31-ring grooves consist of 16 fuel ring grooves alter- nating with 15 oxidizer ring grooves. The fuel ring grooves are supplied with fuel from the injector manifold by 32 radial pasllages, and the oxidizer ring. grooves are supplied with oxidizer from the oxidizer dome by axially drilled holes. Fourteen copper rings, orifice-drilled to pro- vide a doublet fuel-on-fuel impingement, and 2 circular, fuel-cooled copper baffles are brazed to the fuel ring grooves. Fifteen copper 1- 9A Change No. 8 - 19 February 1970 CHAMBER WALL F "y"lNDEX PtN TUBE NO.1 A R-3896-1 Section I Paragraphs 1- 20 to 1- 23 1-20. THRUST CHAMBER OXIDIZER DOME AND MANIFOLD DESCRIPTION. The thrust chamber oxidizer dome and manifold assembly (figure 1-10) distributes oxidizer to the thrust chamber injector and provides the attach point for the gimbal assembly. The assembly is a welded, CRES and nickel-base alloy unit con- sisting of a dome body and a torus manifold. The dome body contains the attaching flange and support posts for interfacing with the injec- tor, and a slotted and drilled mounting flange for interfacing with the gimbal assembly. The manifold incorporates two inlets 180 degrees apart, for mounting the No. 1 and No. 2 oxi- dizer valves, and a flanged boss for the heat exchanger oxidizer supply line. To prevent vortexing of the oxidizer, the manifold is iso- lated into two compartments by two torus dams welded at 90 llegrees from the inlets. 1-21. GIMBAL BEARING ASSEMBLY DE- SCRIPTION. The gimbal bearing assembly (figure 1-11) permits the engine assembly to be rotated about its x- and z-axes and thereby provides limited control of the engine thrust vector to enable the vehicle's guidance system to perform vehicle pitch, yaw, and roll commands. The gimbal bearing assembly is also the principal thrust interface between the engine and vehicle or test stand. The assembly is a spherical, low-friction, steel uniVersal JOint, incorporating ball- and socket-type bearing surfaces. A composition of Teflon- impregnated Fiberglass (Fabroid) is bonded to the bearing surfaces of the sockets. The main components of the gimbal assembly consist of a m isalinement plate, a seat, a bol1y, a block, and a shaft. A silicone-impregnated Fiberglass boot around the gimbal bearing protects the assembly from adverse environmental condi- tions. 1- 22. The misalinement plate is the interface between the oxidizer llome and gimbal assembly and incorporates guides and threaded- type ad- justment devices to laterally position the assembly. Eight slotted troles in the plate flange. which coincide with eight threaded inserts in the dome flange, allow lateral adj ustment of the plate along the x-axis. Eight oversized holes in the seat flange, coinciding with the slotted holes in the plate, allow lateral adjustment of the seat along the z-axis. The bottom guide recesses into a guide slot machined into the dome. The seat rests on the misalinement plate and has a guide slot into which the upper guide of the mis- alinement plate recesses. The seat contains the Fabroid-Iined socket section within which the ball sections of the body move anll incorporates two arms that support the shaft. The body is the engine interface to the vehicle Dr test stand structure. The body incorporates the ball section for the seat socket and the Fabroid-lined socket section for the ball section of the block. The block contains the ball section for the Fabtoid-lined socket section of the body. The sides of the block are lined with Fabroid as are the surfaces of the hole into which the shaft fits. The shaft, through the support arms of the seat, transmits all bearing loads between the engine and vehicle. The shaft is prevented from rotating and moving axially by two plug and screw re- tainers. The Fabroid liners of the gimbal assembly are lubricated at assembly and require no furthe r lubr ication. 1-23. THRUST CHAMBER NOZZLE EXTE;.i- S10N DESCRIPTION. The nozzle extension (figure 1-12) increases the thrust chamber ex- pansion ratio to the ratio that provides an optimum average of engine performance over the powered phase of the booster stage trajectory. The nozzle extension is of Welded construction. incorporating nickle- base-alloy inner and outer walls, separated by z-sections with CRES re- inforCing channel bands welded to the outer wall circumference. FUm cooling of the inner walls is achieved by injecting turbine exhausi gas, supplied to the cavity between the walls by the turbine exhaust manifold, into the thrust chamber exhaust stream through injector slots formed by 23 rows of overlapping shingles that form the inner wall. The thrust chamber nozzle exten- sion is bolted to the thrust chamber exit- end ring after the engine is installed in the vehicle. Change No. 6 - 19 February 1970 1-9B Section I R- 3896-1 HEAT EXCfiA!';GER OXIDIZER Sl:PPLY THRtST 01-. PRESSl. RE ~ S\\1TCH ASSE:.mLY nOEL ~tA~lrOLD ......-, . -... "i', " ..~ , • THROAT PLl'G INSERT OXIDIZER DOME AND MANIFOLD BYPASS ORIFICE OOWN TUBE HYPERGOL FEED UNE SENSING PORT CAlJBRATION PRESSURE PORT~:J"~, "/ 1 OUTER INJECTOR SEAL L': ~ / FLEL MANlFOl.D DRAlN (2) VlEWO AeTATED 90° ITEL lr-LET SPUTTER ISERT FLU1::D:...__-,,-,,~ nLL PORT OXIDIZER I~LET SPLITTER Fl·l·-lSA 1-10 Figure 1-10. Thrust Chamber Oxidizer Dome Change No. 8 - 19 February 1970 R-3896-1 section I Paragraphs 1-24 to 1-25 I' I I _~9.R Z-AXIS *AXIS t i, " r.., SEAT I GIMBAL ~ST'ALLATIOM TEFLON- nSERGLASS COMPOSITION LINE:Fl. F"l-1-46 Figure 1-11. Gimbal Bearing 1-24. TURBOPUMP DESCRIPTION. 1-25. The turbopump assembly, designated the MK-IO turbopump, delivers propellants to the engine system at rated pressures and fiowrates. The assembly is mounted parallel to the thrust chamber longitudinal centerline and is pri- marily supported by two three-legged outrigger assemblies welded to the chamber body and by the four high-pressure propellant ducts in- stalled between the turbopump and the thrust chamber. The turbopump assembly (figures 1-13 and 1-14) is comprised of two centrifugal pumps, mounted back-lo-back on a common shaft, directly driven by a two-stage, velocity compounded, impulse gas turbine. The main shaft and the rotating parts that attach directly to the shaft are dynamically balanced as an assembly prior to final assembly of the turbo- pump assembly. Plugs in the fuel impeller and weights in the turbine wheels are installed. as required during the procedures, to achieve the required balance. Dual discharge ports on each of the pumps balance the radial loads on the assembly. The shaft is supported by two electrically heated, fuel-cooled ball bearing assemblies at the oxidizer pump area, and one fuel-cooled roller bearing assembly at the tur- bine area. (See figure 1-15 for a cutaway YleW of the turbopump.) Six carbon- nose and three carbon-segmented seals, augmented by plastIc (Kel-F, Teflon) and synthetic rubber (Buna-N, Viton-A) seals, perform sealing functions to isolate the propellants, cooling fluid, and hot gases to their respective areas. Change No.8 - 19 February 1910 1-11 Section I R-3896-1 SfCTION B-B IGNITER BOSS - / (TYP) SfCTION A·A rn~~__/~ III ~ _ n. I r m SHEAR SUMO N'lJT 1/ ~ I ' (12 PLACES) ,I " ~I I /, ~, ='\ -- In SHEAR BLIND NUT~, ~__ ("/2 PLACES) ~~~. =--- ROTATED 4~· TU~NELSUPPORT BRACKETS (TYP OXIDIZER AND F\lEL DRAIN UNE SIDE) ~~~~~~l'- WmaDIZER DRAIN ~ UNE SIDE mENOniES mCORPORAnNQ MD140 CHANGE Figure 1·12. Thrust Chamber Nozzle Extension 1-12 Change No.7· 18 August 1969