Nasaco Saturn S-1 Stage User manual

,
J
HANDLING, TRANSPORTING
AND
ERECTION INSTRUCTIONS
SATURN S-l STAGE, SA-1
: .... GEORGE C. MARSHALL SPACE FLIGHT CENTER
." HTTP://HEROICRELICS.ORG
HUNTSVILLE ALABAMA

TITLE
Handling, T ranspor in g, And
Erect ion Inst ruc t ions, Sa turn S =1
S ta ge ~ SA =1
T ABLE OF C ON T ENTS
GEORGE c.
MARSHALL
SPACE FLIGHT CENTER
PROCEDURE
DATE
1
PAGE
1
OF 147
Paragraph
Page
LIST OF ILLUSTRA T IONS VOOOGOOOOOOOOOOOOOOOO O . OOOCOOOOOQO OOO OOOOOOOOOOOO OO O 3
INTRODUCTION 0 000 000 Q <:) I,) U 0 0 (J 0 000000 0 0 0 0 0 0 I) 0 0 00000.) 0 0 0 0 0 (.I 0 0 000 000000 0000 0 0 000 5
CHAPTER I T RANSPOR TA TI ON , HANDL ING, AND EREC T ION AT S TATIC T ES T T OWER 000 7
10 PREPARING BOOSTER FOR ERECTION ooooooooo o oooooooooooooo o ooopoooooooooo 7
10 1 Posi t ioning T ranspor t er (J = AF = 2004) oooooooooooooooouoooooooooooo o'o 7
102 Ins t alling Bumper Assem b ly ( D= 10426438) , Two Bumpers (D= 10426434) ,
and
Two Cable Assemblies (J =1 0424771) oo oo ooo . o o oouoooooooooo . ooooo 7
" 10 3 Removal Procedu re Rear Ring Se c 'ti ons (J= AF 91 2 00 4=2 =0 000000000000000 11
2 0 ER ECTI . NG BOOS T ER 0 I,) (J 0 0 0 v 0 0 0 0 0 0 0 (.0 (J 0 (J 0 0 u 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 • a 0 0 0 0 • 0 0 Q (I I) C 0 20
2 01 Posi t ~oning Tr an sport er and At tac h in g Ere ct ion Cables 000000000000000 20
2 ~ 2 Removing Boos t er from T ranspor t er and Pos itioni ng on Tower
T hrus t Ring 0,) a 0 0 0 () 0 0 0 0 0 0 a 0 () U 0 0 0 0 a 0 0 0 0 (J C. 0 0 0 0 0 v 0 0 0 0 0 G OO . 0 a 0 0 0 0 0 0 0 (I 0 0 0 28
30 REMOVING BOOS T ER FROM TEST T OWER Ovooooouooooooooooooooo o ooooooooooouo 35
3 01 Prepar ing Boos t er f or Removal ooooovooo"oooo o ooo ooooo ooooooooooooo ooo 35
302 Removing Boos t er fr om To we r Thrust Ring and Pos iti o ni ng on
Trans por t er 0 0 0 0.) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 a 0 0 0 0 " 0 \.'I 0 0 0 0 0 0 0 0 0 0 0 0 0 0 (J 0 0 0 0 0;1 0 0 37
303 Ins t alla t ion Proced ure Rear Ring Se ct ion s (J= AF =1 2004=2=0) 00 0 0000000 40
304 Removing Bumper Assem bly (D=1 0426 43 8) , Tw o Bumpers (D= 10426434)
and Two Ca ble Assemblies (J =1 0424771) 0000000000 00 00 000.' 0 0000000000 44
CHAPTER II TRANSPOR TA TI ON , HANDL I NG
9
AND EREC TI ON AT CAPE CANAVERAL 00000 47
10 PREPAR IN G BOOS T ER FOR ERE CTIO N 00000000000000000000000000 00000 00000000 47
1 01 Preparing Service St r uc t ure fo r Er ecti on ooocooOoooooooooooooo,ooo oooo 47
102 Posi t ioning Tran spor t er (J= AF = 2004 0000000000000000000 . 000000 0 00000 47
103 Insta lli ng Beam Weldmen t (J =1 0426 67 5) and Forward Sling Assemblies
(J """, 10426668) 0 0 () 0 0 0 0 0 u 0 v 0 0 0 0 0 Q 0 0 0 0 0 coo 0 0 0 I) 0 0 0 0 0 0 0 I;) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 51

EORGE C. MARSHALL SPACE FLIGHT CENTER
PROCEDURE
EP =1 41
PAGE OF
2 1 47
TABLE OF CON T EN TS (Con o)
Paragraph Page
104 Remova l Procedure Fo rward Ri ng Sec t io ns (J= AF =12 004 =3=O) 000000 000 00 00 54
10 5 Removal Procedure Rear Ring Se cti ons (J = AF =1 200 4= 2=O) 0000000000000000 60
:2 0 EREC TING BOO ST ER I) 0 0 0 0 0 0 0 0 0 0 0 0 8 0 0 0 (I Q 0 0 0 0 0 0 0 0 0 0 0 0 G OO 0 0 0 0 0 0 Q 0 0 0 0 0 " 0 0 0 e 0 0 0 64
2 01 Posit ion i ng Transport er and A tta ching Ca b les 0000000 0 0000000000000000 0 64
,20 2 Remov in g Boos t er from Transport er and Pos iti oning on Launch Pedestal 0 72
30 REMOVING BOOS T ER FROM LAUNCH PEDES T AL 00000000000000000000000 00000000 0. 79
40 REMOV I NG RING SEC TI ONS WITH FIN I IDEN T IFICATION AND PRESERV I NG ALL
RING DE T AILS AND A TT ACHING HARDWARE 0000000 00 0000000 0 00000 0.000000000 80
4 .1 Remov in g Forwa rd and Rear Ring Secti ons w ith Fin I Ident ification
front Transpor te r I) 0 0 (.) 0 0 0 0 0 0 0 0 0 0 0 0 4) 0 0 0 00 0 0 0 0 0 0 u 0 0 0 0 • 0 0 0 0 0 0 0 0 I) I.) 0 0 0 0 0 0 0 8D
4 ~ 2 Preservi ng Forward and Rear Ring De ta i!L s and A tt achi ng Hardware a 0 eo 00 82
CHAPTER II I GENERAL INS TR UCTIO NS FOR T HE 8=1 T RANSPOR T ER 00 00 0000 000 0000 00 83

PAGE OF
EP-141 3 147
LIST
OF ILLUSTRATIONS
Figure Title Page
1.
Posi t ioning Equipment at Sta t ic Test Tower 00 00 •• 00 . 0••0 ••• •0•. 00 8
2" Removing Doors and Pla t es oooe ooo oooo o ooocooooooo o CJO O OOOClO O OO OOOO 9
3. Ins t alling Bu mp e rs and Cable Assemblies 0.000 •• 0 ••• 0 •••• 00 •. 000.0 10
40 Positioning Horizontal Pla tform and Personnel 000 00 0. 00 " 00 '. 00 .. 12
5. Removal of Rear Ring Sec
ti ons (J = AF =1 2004-2~0 ) 0.0 00000 . 00 •• ••• 0. 13
6. Rear Ring Sect ion At taching Poin ts ••• 000. 0. 0.00.0 •• 0, '0 .'0 ••0" 0 14
7. Removal of Rear Ri ng Sec ti on at O ut rigger No
o 2
••• 0 .. 0 .. . .. 00.0. 18
8. Identification of Fin Line and Ou t rigger Numbers 0'0.0.00.00 •• 0 .. 19
9Q Erect ion Beam Inst alla t ion oe e oooooooooo oo o oo • •• oo • • o ooooo ooeoo oo 21
100 At t ach i ng Erec t ion Beam and Cable Assemblies 0' 0000' 000 00 00'0 0" 0 23
11 • Connect ing Af t Cable Assembly ••• 00 . o •• 0••• 0000•00•00• 0 ••• 0 00 . 0•• 25
1
2. Forward Support Clamps o. 00•00•0•0000 •.• 000•0 .• 0. 00,' •000.'0 ••• 0••• 27
13 0 Lifting Boost er off Transpor t er 0•• 0• • 000 ..• 0 .•.• 00 •• 0. 0000.000 •• 29
14. Boost
er Stabiliza t ion Prepara t ory t o Lif t ing off Transporter • . 0. 31
15. Boost er in Vert ical Posi t ion 0000000 •••• 0. 0•• •••• 0. 0. 0.0 0.·• ••• ••0 33
160 Posi ti oning Boost er on Support Bracket s 0.00 . 0 0000 000 . 0 ••••••. 0•• 36
17. Preparing Serv ice St ruc t ure for Erec t ion .000.00 •• • 00 •••••0 .. .... 48
18. Posi ti oning Equipment at Firing Si t e 0 •••. 00 0. 0 •• 0. 0 •.••••.. 0. 0 .. 49
19. Preparing Boost er for Erec ti on 00•• ••• 0•••0 •. 00000•0•0••• p 0000. . • 52
20. Installa ti on of Beam Weldmen t and Forward Sling Assemblies 00 •• 00 53
21. Removing Forward Ring Sect ions (J = AF- 1 2004 ~ 3 ~ 0 ) .~ 0. 00 ••• 0' o . 00" 0 55
22. Forward Ring Section At taching Poin t s ••• 0. .... 00 . 0•• 00 ... . .. 0•• 0 56
23 . Forward Ring Sec ti on Removal Procedures .0 .0 •••• 00 •••• •0. 00 . • 00 . 0 57
24 . Attaching A ft and Forward Sling Assemblies . 00 0 ••• • 00 .. 0 ••••• 0 0.. 65

GEORGE C. MARSHALL SPACE FLIGHT CENTER
PROCEDURE
EP ,·,1 41
Figure
PAGE
4 OF 147
LIST OF ILLUSTRATIONS (Con o)
Ti t
le Page
Connec
ti ng Erect ing Beam and Forward Slin g Assemb l ies 00000 • •• 0 .. 68
260 L ifti ng Bo ost er off Transpor er 0 •• 0 •••• • 0 • • 0 •• 0 • ••••• • •• •• 00. • • • 69
27 . 8-1 Stage Cen 't er-or - Gravi ty Di agram •••••• •0 • • 0 • • •••• •• •• • 0 • • •• • • 71
28 . Remo vi ng Af t Cable Assembly and Posi t ioni ng Booster on Launch
Pedes t al 0 III 0 . 000 •• 0.0 Q 0 • • " 0 • • 0 e • • 0 II 0 . 0 0 0 . .... ... 0 0 •••• ••• " 0 0 •• 00 . 75
29. Boost er - to- Launch Pedesta l Orien t atio n Diagram.. . . .. . .. .... ... .. 77
30. P osi t ioning Boost er on Support A rms and Holddown Arms .0... .... .. 78
31 0 Rear Ri ng Support Cl amp s Q. 0 0 • 0 0 • ·0 u • •• 0 •• 0 • III 0 • 0 ••• 0 • !oJ • III ••• 0 • • • • • • 81

INT RO DU CTI ON
Thi s manua l pr ov ide s t he nece ss ar y in st r uct i ons for t rans p or t ing, handling ,
and
erec t ing the Sa t ur n S =I B oo s t e r ~ ef fecti v it y SA =1 and is di vided in t o t hree
chapt ers 0 Chap t er I contai ns in st ru cti ons at t he sta t ic t es t tower. Chap te r
II con tai ns ins t ruct i ons at t he Cap e Canaveral f i ri ng si t e. Chap t er III con=
ta ins opera t i ng ins t ruc ti ons for t he Sa t urn S=I T ranspor t er .
ER
Chap te r I co nsi st s of st ep=by=st ep pr ocedures for r e mov i ng the rear ri ng
sec t ions, pos it ion ing and er ectin g the Boost er i n t he sta ti c t es t t ower, pres er-
va
tion of t ool i ng , pos iti oning t he Boost er on the t ransp or t er, and reassembly
of the rear ri ng se ct i ons t o t he Boo st er af t er s ta t i c t es t firing .
Chap t er II consi st s of st ep=by=st ep proc e dures for removing the forward and
rear ring sec ti ons, posi t i on in g and erec ti ng 'the Boost er from the launch
pedest al, and preserva t i on of t ool ing for sh ippi ng .
A complet e
man ual con taini ng ge neral in st ruc ti ons for the Sa t urn S=I
T ranspor t er and i n cl ud in g a separa t e Tabl e of Con tent s , Lis t of Ill ust ra ti ons,
and In t rod uc ti on i s in ser te d i n thi s manual as Chap t er III .
Eq ui pmen t e ssen ti al t o pr oper ha ndlin g of t he Boost er at t he sta t ic t es t
tower and at t he Cape Canaveral f
irin g s it e i nclu des the fo l lowing: t rans =
por t e r, t ow i ng t rac t or , gant ry cra ne, mo bil e c rane , fork l i f t , horizon t al and
t
ranspor tat i on r in g pl at forms . Sp eci al hardware assures safe and efficient
handling of the Boost er d urin g r e mov al and erec ti on.
T
his publ icat i on i s a com bin ed eff or t of the M= LOD, M =T EST, and M- F&AE
Di vi sions 0

PROCEDURE
PAGE
OF

CHAP T ER I
TRANSPORTATION, HANDLING, AND EREC TI ON AT STATIC
T ES T T OWER
1. PREPARING BOOS T ER FOR ERECTION 0
1.1 Pos iti oning Transpor t er (J=AF =1 2004 )o
1.1. 1 Pos iti on t ranspor t er on nort h side of sta tic t es t t ower at a
r i ght
angle t o defle ct or p it and aline wit h deflec t or pi t
bridging at a di s ta nce which will provide sufficien t working
area around the t ranspor t er for the mobile crane and fork lift .
(See figure 1 for the re l a ti ve posi t ions of the equipment. )
1. 1.2 Lock t ranspor t er brakes and chock wheels.
1
.2 Installing Bumper Assembly (D-104264 38 ). Two Bumpers (D-1042643~ ) !
and Two Cable Assemblies (J- 1 0424771~
1. 2.1 Move t rac t or and t ow bar clear of t he forward end of the
boost
er .
1.2.2 Using
fork lift, raise t ranspor tat ion ring pla tform and
personnel to a heigh t necessary for a tt ach i ng bumper assembly
(D-10426438) , t wo bumpers (D-10426434 ), and cable assemblies
(J -1 0424771) . (See fig u re 2 .)
1. 2.1 .1 Remove doors (D-10411708) and pl at es (D-104 11 753)
a tt ached t o in t er st age fairing and second st age
adap t er ~o gain access t o bumper and forward sling
assembly a ttac hing poi nt s. At ta ching poin t s are at
I=beams
No . 3, 4, 5, 6, and 7.
1. 2.1.2 Remove a tt ach i ng hardware that secures in t ers tage
fairing t o second s ta ge adapt er at at taching po i nt s
for bumper assemblies and f orward sl ing assemblies as
shown in figure 2.
NO T E: All doors and a tta ching hardware t o be packaged
and st
ored o Th i s hardware wi ll be ins t alled af t er t he
boost er has been erec ted in the t es t t ower. See
figure 2 for lis t of at taching hardware.
1 .2 01 .3 In st all bump er assembly ( D- 10426438) in accordance
wi t h detai l A, figure 3.
1.201.4
Ins t all bumpers (D-10426434) in accordance wi t h detail
B ~ figure 3.

PROCEDURE
EP =141
PAGE OF
8 1 47
FIG.I POSITIONING EQUIPMENT AT STATIC TEST TOWER

----- --,-- -- --------------- --- ---_._-._---------- ... _----- --- -- ---- ------- -------- --
PIN ~
(C-10411722)
(I) REQ'O
NUT J_
NAS-1022 ~
(I) REQ'O I
[I
"~?,-.-
1%2'\
--
----
--- 7\
L
U
E§
- __ U
D
~
~------SCREW
/ 7513-1032-12A
i ~ .r-PLATE
~
~ S> ~ (0-10411753)
I / I)
I) Q ' (~~~~1I723)
I ~ ~ REQ'O
l1 i ' 1 '1
I I ~ {f)-~OE4J!621l
I I
I
~ r-~~J - 1022-C8
I)
~ (I) REQ'O
,
~
LOCK PLATE
(C-10411724)
,,1, ..... (Il REQ'O
~ I-----SCREW
AN501AC416-8
(I) REQ ' O
~---OOOR
(0-10411708)
'-----~-----SCREW
7513 -1032-12A
(10) REQ' 0
-0
DETAIL A
FIG.2 REMOVING DOORS AND PLATES
REF. OWG .
10411701