Rocketdyne Field Laboratory Mechanics Handbook

PUBLICATION 513-P-2 REV 9.
7 5
FIELD LABORATORIE S
MECHANIC'S HANDBOO K
A TECHNICAL TRAINING PUBLICATION
PREPARED B Y
TNEROCKETDYNE TRAINING DEPARTMEN T
• Rockwell International
Rocketdyne Division
CONFID ENTIAL LEVEL I - UNDER PROTECTIVE ORDER,

BNAU87585U6
United States District Court for the Central District of
California, No. CV 97-1554
H DMSp01659431
PBEFACE
The Mecbanic ' s Handbook was prepared to provide Rocketdyne Field Laboratories person-
nel with a central soaree of fundamental reference material . The Training Department
has compiled this manual from information obtained from numerous official sources .
However ,. as new techniques and applications are adapted and as new equipment replaces
old, thia and subsequent editions will become obsolete . This probability has been
anticipated in a type of binding which permits present sections to be revised and new
sections to be developed and included .
Blank pages are provided at the emd of this baadbook . It is hoped that the holder of
this manual will not only use these pages for his permanent notes but will use them
to record his impresaiono and suggestions and direct them to Department 051, Train-
ing .
Normally a few of the areas covered by a reference volume will be of interest to any
one individual . For this reason it is suggested that the user acquaint himself with
the general nature of the contents nod more carefully familiarize himself with those
portions which are of immediate interest. Because of the limited space available and
because of changing usages, no pretense to completeness or to applicability at any
given time can be made for this volume . Corporation , Division , and departmental
• references remain the only authoritative sources of information .
The information in this manual is for reference purposes only . The Engineering Draw-
ing, Engineering York Bequest, Process Specification , Standards Book and Field Labo-
ratories Manual are the official sources of information .
CONFTDENTIA1, l,EV El, 1- t 1NDER PROTECTTVF. ORI)ER ,

BNA0875850 7
H DMSp01659432
S
CONTENT S
Section 1 . GENERAL 1NFOQ tTION

Section 2 USEFUL. INFORMATION
Section 3 . . . . . . . . . . . . . . PIPE, PURE, AND FITTINGS

Section 4 . . . . . . . . . . . . . . VALVES AMID REGULATORS
Section 5 . . . . . . . . . . . . . . FAST@4R8
Section 6 . . . . . . . . . . . . . . LUBRICANTS , GASREFS, SEALS AND PAC$AGf&
Section 7 . . . . . . . . . . . . . . LIQUID PROPELLANTS AND SOLVENT S
Section B . . . . . . . . . . . . . . RIGGING
Section 9 . . . . . . . . . . . . . . ELECTRICITY
Section lO . . . . . . . . . . . . . . RAND TOOLS
Section 11 . . . . . . . . . . . . . . MISCELLAN 1JS
CONFIDENTIAL 1,TVP1, T - i7N1)T1i PROTPCTTVP ORDPT1 ,

BNA08758508
California, no. CV 97-1554
H DMSp01659433
SECTION 1
GE LbL I1rFORM 3.TION
CONTENTS
Page
Map of Santa Susana Field Laboratory (SSFL) 1-1
Nap of Edwards Field Laboratory (FL) . . . . . . . . . . . . . . . . . . . . 1-2
Map of Nevada Field Laboratory (NFL) . . . . . . . . . . . . . . . . . . . . 1-3
Mission of Field Laboratoriea . . . . . . . . . . . . . . . . . . . . . . . . 1-i
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Good Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Inforsation Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Conservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Abbreviations and Def iaitions in Use at

Rocketdyne Field Laboratories . . . . . . . . . . . . . . . . . . . . . . 1-6
•
i
CONFIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA08758509
H DMSp01659434
• 0 •
SANTA SUSANA FIELD LABORATOR Y
_I L ENTRANCE
AREA 2, SERVIC E TO SSFL
9 AONIN .. . I ' :I GUARD HOUSE,
QI'~I
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01
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IT t~ "S'PARKIN I F GUARD HOUSE . MEAT

SERVICE AREA
i t ~$,\ RESEARC H
AREA I
.'. fl , HAPPY VALLEY
A .1 . .. .~'
AREA 111 I AREA .
J I
ARE A
COCA 'T
DELT A CTL-S
AREA 11
NBCHAHIC ' S HANDBOOK
•
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BNA0875851 1
H DMSp01659436
GfNEaAL INFORMATIO N
REDACTED
0
NEVADA FIELD LABORATOR Y

0
1- 3

BNAU875851 2
H DMSp01659437
MECHANIC' S 850 DmnOIC
MISSION OF FIELD LABORATORIE S
The mission of the Field Laboratories test units may be summ rized as follows :
1 . To perform all tests as schedule d
2 . Each test shall fulfill its predetermined objective s
3 . All test measurements shall conform with required accuracy and precision
I. . All operations shall be performed with safety and economy
Daily operations , whether simple or complex , can result in loss of one or more of the
above mission items if they are not accomplished properly . Racket engines , rocket
components and test facility systems contain numerous openings and many electrical
connections which may allow contamination , connection of wrong lines , mismatching of
parts, improper assembly of threaded fastenings or flanges and improper electrical
nonnoc±i000 . The consequences of a wrong act can be disastrous and therefore moot be
avoided through alertness , good workmanship , and adherence to applicable procedures
and check lists . Remember , when in doubt , ask -- do not leave anything to chance :
SAFEPY
Your safety and the safety of your fellow employees can only be assured if you under-
stand the potential hazards that may exist in your work area , follow the appropriate •
procedures , and utilize the proper equipment . Unsafe conditions should he brought to
the attention of your superv isor , safety committeeman , or Industrial hygiene and
Safety representative . Such obse rv ations are appreciated and may aid in preventing
personnel injuries .
Handling toxic or flammable materials, working around cryogenic or high-pressure sys-

tems, and similar activities usually require special training . An employee should
not attempt any task until he is fully aware of the hazards involved and the proper
methods to perform the job safely . When not sure, ask the leadmsa or supe rv isor .
Some jobs require specific items of protective clothing or equipment -- safety

glasses, supplied air breathing equipment, propellant handler's suit, etc . Careful
job planning will determine when these items are required . Proper selection and use
of equipment will protect you .
The safety of field laboratory personnel can only be assured if each individual
assumes personal responsibility for performing his work tasks in the correct manner .
GOOD ROUSEIiEPING
Good workmanship and safety depend on good housekeeping . Remember these requirements
for good housekeeping :
1 . Small utility items (e .g . nuts, bolts, washers, tubing fittings ; pipe fittings,
electrical connectors, electrical terminals, dust caps , etc .), small sera items
(e .g . pieces of wire, pieces of welding rod, metal scraps, damaged or unusable
•
1- o

BNA0875851 3
H DMSp01659438
GENERAL INFORMATIO N
•
small utility items, etc .) or tools shall never be placed on any ledge or other-
wise convenient surface of an engine , stand or test cell for any period of time,
regardless of the operation being performed on the engine or the stand system .
The only acceptable location o repository for small utility items o a test
stand is in bread pans , trays and tote boxes . These are to be placed on the
floor or work platform located so that they do not constitute a tripping hazard .
Tools are to be kept about one's person or in the tool box located in the same
place as the pans , trays or tote boxes .
2 . The test stand and engine shall be free of scrap items at all times . While this
concept does not hold for stand in process of construction or modification, rea-
sonable efforts should be made towards this end .
3 . The vicinity of all test areas and support areas are to be free of small utility
items and small scrap items .
INFORMATION 50 11S CES
To achieve required standardization , quality, and maximum safety, several documents

have been published which are revised periodically to keep abreast of new require-
ments and changing technology . These documents axe :
FIELD LABORATORIES MAMIAL (FLN)
This manual contains :
1 . Directives -- applicable to all field laboratorie s
• 2 . Index of safety oriented ROP's -- applicable to all field laboratorie s
3 . Field laboratory procedures -- applicable to a particular field laboratory
4 . Field laboratory manager 's bulletins -- applicable to a particular field

laboratory
5 . Group and project instructions -- applicable to a particular test group . .
FIBINEFRING PROCESS SPECIFICATIONS
Process and material specifications concerned with rocket engines and their related
equipment contain such detailed instructions as :
1 . Manufacture
2 . Installation
3 . Testing
4 . Inspection
5 . Material s
For reference purposes , some of the more commonly used Standard Parts and Processes
are described in this hanual . The source of the information concerning any of the
Standard Parts or Processes is as indicated above and supersedes and voids any in-
formation which follows often any difference exists .
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BNAU875851 4
H DMSp01659439
MECHANICIS HANDBOOK
CONSFBVATION •
Damaged or excess materials are sent to the reclamation yard . There they are
screened , and either returned to service or disposed of through surplus sales .
The reclamation yard is a valuable source of materials for test equipment and can
represent a considerable savings in both time and cost to the user .
When small utility items , such as nuts, bolts , cap screws , washers, tubing fittings,
pipe fittings , electrical connectors , electrical terminals , caps, covers , plugs,
etc ., are removed from an engine , component , or the facility system , they shall be
used in the subsequent reassembly unless damage , wear , work order, process specifica-
tion, or other written instructions preclude reuse. In either case, whether they are
used or not , all small utility items shall be accounted for when the reassembly i s
omplete _ The storage of these small utility items for reuse shall be such that they
cannot be inadvertently introduced as contamination into the engine , component or
facility system .
ABBREVIATIONS AND DEFINITIONS IN USE

AT
ROCKETDYNE FIELD LABORATORIE S
Al . . . . . . . . . . . . . . Atomics International , Division of North American

Aviation, Inc .
AN . . . . . . . . . . . . . . Air Force-Navy aeronautical standard parts

designation
AND . . . . . . . . . . . . . Air Force-Navy aeronautical design standard
•
ASA . . . . . . . . . . . . . American Standards Association
ASME . . . . . . . . . . . . . American Society of Mechanical Engineers
ASTM . . . . . . . . . . . . . American Society for Testing Materials
CANO . . . . . . . . . . . . . Canoga Park Facility
C .C, C .H ., or R .C . . . . . . . Control Center , Control House, or Recording Center --

the concrete building from which rocket engine tests
are controlled
CTL . . . . . . . . . . . . . Components Teat Laboratory -- thoeo facilities where

rocket engine components such as turbopumps and gas
generators are tested
CTF . . . . . . . . . . . . . Chlorine trifluoride
DETA Diethyleme triamine -- a rocket fuel additive
EAAT . . . . . . . . . . . . . Edward Air Force Base
ECS . . . . . . . . . . . . . Electrical Control Station - an installation

adjacent to the teat stand which connects by cable
to the control center
EFL . . . . . . . . . . . . . Edwards Field Laboratory -- the rocket test facility

at EAFS
•
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BNA0875851 5
H DMSp01659440
GENERAL INFOBMATION
EL . . . . . . . . . . . . . . Equipment Laboratory -- a facility which cleans and

• services equipmen t
W24 Box . . . . . . . . . . . . Electromechanical box containing control valves which

link pneumatics to end device s
Engine Console . . . . . . . . A panel in the control center containing the switches

and indicator lights necessary to the control of the
rocket engine on the test stand
EWR . . . . . . . . . . . . . Engineering work reques t
Facility Console . . . . . . . An electrical panel in the control center which con-

tains the control switches and indicator lights nec-
essary to the operation of the test stand but not the
rocket engine .
FIM . . . . . . . . . . . . . Field Laboratories Manual
FLOE . . . . . . . . . . . . . Mixture of liquid fluorine and liquid oxygen
GYP . . . . . . . . . . . . . Government Furnished Property . Government property

not used in airora£t (such as machinery , desks,
chairs )
GO . . . . . . . . . . . . . . . Gas Generator -- the rocket engine component which

drives the turbopump
GN2 . . . . . . . . . . . . . Gaseous nitrogen
GOX . . . . . . . . . . . . . Gaseous oxygen
• He . . . . . . . . . . . . . . Helium
H202 . . . . . . . . . . . . . Hydrogen peroxide
Bydyne . . . . . . . . . . . . Mixture of IIDMH and DELI ( propellant)
HZ (N2 94) . . . . . . . . . . . Hydrazine ( anhydrous )
ICBM . . . . . . . . . . . . . Intercontinental ballistic missile
ICC . . . . . . . . . . . . . Interstate Commerce Commission
ID . . . . . . . . . . . . . . Inside diameter
IL . . . . . . . . . . . . . . Instrument Laboratory
IL . . . . . . . . . . . . . . Internal letter ; NA A
IRFNA . . . . . . . . . . . . Inhibited red fuming ni tr ic acid
IBM . . . . . . . . . . . . . Intermediate range ballistic missile
JAN . . . . . . . . . . . . . Joint Army - Navy
.T Boz Tunctice bar -- a ent place to make an author-

ized change in an electrical circui t
0
1-7
CDNFID ENTIAL LEVEL I- UNDER PROTECTIVE ORDER ,

BNA0875851 6
H DMSp01659441
MEC3ANICIS HANDBOOK
JIR . . . . . . . . . . . . . . Job Improvement Reques t
. . . . . . . . . . . . Job Order (Form 72-NO ) . An order by Industrial 0

J .0 . .
Engineering , approved by proper levels of management,
instructing a department or group of departments to
accomplish a task in order to complete a JIR . (See
Prooeduros 3-7, 3-9, Dept . 564 Operating Manual . )
JP . . . . . . . . . . . . . . Jet propellant
LF2 . . . . . . . . . . . . . . Liquid fluorine
LH2 . . . . . . . . . . . . . . Liquid hydrogen
LN2 . . . . . . . . . . . . . . Liquid nitrogen
L-3000 . . . . . . . . . . . . Designation for a storage tank which holds an amount

of LOX capable of forming 3,000,000 cubic feet of
oxygen gas at standard temperature and pressure
LOX or .02
1 . . . . . . . . . . Liquid oxygen
MAC . . . . . . . . . . . . . . Marimum Allowable Concentration
MACE . . . . . . . . . . . . . Missile and Control Equipment
MIL . . . . . . . . . . . . . . Military - a prefi x
MMH . . . . . . . . . . . . . . Monomethylhydrazin e
MS . . . . . . . . . . . . . . Military Standard -- parts designation
NWO . . . . . . . . . . . . . . Maintenance Work Order Request (Form 615-W-1) -- a

•
job request to the Maintenance Department
NU . . . . . . . . . . . . . . North American Aviation (Property Tag)
NAS . . . . . . . . . . . . . . National Aircraft Standard
NASA . . . . . . . . . . . . . National Aeronautics and Space Administration

(Property Tag)
NC . . . . . . . . . . . . . . National Course -- a screw thread type
NFL . . . . . . . . . . . . . . Nevada Field Laboratory
NPSH . . . . . . . . . . . . . Net positive auction head
NPT . . . . . . . . . . . . . . American National Taper Pipe Thread or

American Standard Taper Pipe Thread
NTO (N204 ) . . . . . . . . . . . Nitr ogen Tetroxide
OD . . . . . . . . . . . . . . Outside diameter
Ord . . . . . . . . . . . . . . Ordnance
Pneumatic Console . . . . . . . A panel containing the necessary equipment to regu-

late pneumatic pressure for use on a test stan d
1-S •
CONFID ENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA0875851 7
H DMSp01659442
GEIBBAL INFORMATION
•
PB . . . . . . . . . . . . . Pentaboran e
PSQ . . . . . . . . . . . . . Personnel Security Questionnaire
Purge A cleaning operation for systems , enginest and com-

ponents in which a fluid (usually gaseous ) in caused
to flow through the syste m
REPM . . . . . . . . . . . . . Rocketdyne Engineering Procedures Manual
RFNA . . . . . . . . . . . . . Red fuming nitric acid
RIDAP System . . . . . . . . . Rocketdyne Integrated Data Acquisition and Processing

System
RAP Rocketdyne Operating Policies and Procedures
RP-1 . . . . . . . . . . . . . Rocket Propellan t
RSM . . . . . . . . . . . . . Rocketdyne Stock Manua l
SANSD . . . . . . . . . . . . Santa Susana -- a popular name for SSFL
SUD . . . . . . . . . . . . . Space and Information Systems Division

(a Division of NAA )
TC . . . . . . . . . . . . . . Thrust chambe r
T-Rouse . , . . . . . . . . . The terminal house which contains instrumentation

circuits and instrumentation calibration equipment
• for the adjacent test stand s
TEA . . . . . . . . . . . . . Triothylaluminum
TER . . . . . . . . . . . . . Triethylboron
Test 'Pit . . . . . . . . . . . A steel and concrete structure used for testing com-
ponents of engines and other apparatus at the CTLs
Test Stand . . . . . . . . . . A large engine teat facilit y
TLV , , , , , , , , , , , Threshold Limit Valu e
T .O . . . . . . . . . . . . . . Transfer Order (Rocketdyne Form R-39-M1) . Used

generally to effect the transfer of equipment, sup-
plies, and material s
TRIC Trichloroethylene
TSC . . . . . . . . . . . . . Tooling Supplemental Contract . Government-owned

equipment charged to specific contracts . A tag with
this number must be attached to all equipment owned
by the government
UDMR . . . . . . . . . . . . . Unsymmetrical dimethylhydrazine (rocket fuel)
WFNS . . . . . . . . . . . . . White fuming nitric aci d
WS Weapons system . WS is the prefix of most large

missile contracts
1-9
CDNFID ENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA0875851 8
H DMSp01659443
9 SECTION 2
USEFUL INFORMATION
CONTENTS
Page
Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Weights and Measures . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Piping System Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Welding Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
CDNFT)F,1TTAT, T,F,VF, T, T- ITNDF, R PROTF,CTTVF, ORDER ,

BNA0875851 9
H DMSp01659444
USEFUL INFORMATIO N
CONVERSION TABLE S
•
Fractions of an Inch
To Decimals of an bob and to Millimeter s
Fraction Decimal Millimeter
1/64 . . . . .015625 0 .39688

1/32 .... .03125 0 .79375
3/64 . . . . .046875 1 .19063
1/16 .... .... 0625 1 .5875 0
5/64 . . . . .078125 1 .98438

3/32 .... .09375 2 .38125
7/64 .... .109375 2 .7781 3
1/8 ... . . . . . . . . . . . . . . . . . . . . . . . . . . .... .125 3 .1750 1
9/64 .... .140625 3 .5718 8

5/32 . .... .15625 3 .9687 6
11/64 .... .171875 4 .3656 3
3/16 ... . .... .... .1875 4 .7625 1
13/64 . . . . .203125 5 .1593 9

7/32 .... .... .21875 5 .5562 6
15/64 .... .234375 5 .9531 4
1/4 . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .25 6 .3500 1
17/64 .... .265625 6 .74689

9/32 28125 7 .14376
• 19/64 .... .296875 7 .5406 4
5/16 .3125 7 .9375 2
21/64 . . . . .328125 8 .33439

11/32 . . . . . . . . .34375 8 .7312 7
23/64 .... .359375 9 .1281 4
3/8 . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .375 9 .5250 2
25/64 . . .. .390625 9 .92189

13/32 . . . . .40625 10 .31877
27/64 . . . . .421875 10 .71565
7/16 . . . . . . . . . . . . .4375 11 .1125 2
29/64 . . . . .453125 11 .50940

15/32 . . . . .46875 11 .90627
31/64 .... .484375 12 .3031 5
1/2 . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . .. .5 12 .70002
33/64 .... .515625 13 .09690

17/32 . . .. .53125 13 .49378
35/64 .... .546875 13 .89065
9/16 . . . . . . . . .5625 14 .2875 3
37/64 . . . . .578125 14 .6844 0

19/32 .... .... .59375 15 .0812 8
39/64 .... .609375 15 .4781 6
5/8 .. ....... . ..... .625 15 .87503
•
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BNA08758520
H DMSp01659445
IICHANICIS HANDBOOK
Fraction Decimal Millimeter •
41/64 . .. . .640625 16 .2719 1

21/32 . .. . . 65625 16 .66878
43/64 . .. . .671875 17 .06566
11/16 ... . . . .. . .. . .6875 17 .4625 3
45/64 . . . . .703125 17 .85941

23/32 . . . . . 71875 18 .2562 9
47/64 .... .734375 18 .65316
3/4 . . . . .. . . . . . . . ....... .75 19 .05004
49/64 .. . . .765625 19 .44691

25/32 .... . 78125 19 .84379
51/64 .. . . . 796875 20 .24066
13/16 . . . . . . . . . . . . . . 8125 20 .63754
53/64 ... . .828125 21 .03442

27/32 . . . . .84375 21 .43129
55/64 . . . . .859375 21 .82817
7/8 .. . . .. . . . . . . . . .. . . . . . . . . . . . .. . . . . .875 22 .22504
57/64 . .. . .890625 22 .62192

29/32 . . . . .90625 23 .01880
59/64 921875 23 .41567
15/1 6 .9375 23 .81255
61/64 .... .953125 24 .20942

31/32 -' .96875 24 .60630
63/64 . . .. .984375 25 .00317
1 1 .0 25 .40005 •
•
2-2
CONFH)E,NTTAT, T,E,L"F,T, T - UNDER PROTECTIVE ORDER ,

BNA0875852 1
H DMSp01659446
USEFUL INFORMATIO N
WEIGHTS AND MEAS URES
Length Pressur e
1 in . = 25 .4 mm Absolute pressure = gage pressur e

1 mm = .03937 in . + ambient pressure
1 ft = 30 .48 cm 1 atmosphere = 14.696 psia = 760 mm of
1 mile = 5280 ft Hg = 1013 .2 mb
1 mile = 1 .609 kilometer s 1 psia = 144 lb per sq ft
1 nautical mile = 1 .15156 statute miles 1 psia - 2 .036 in. of Hg
1 nautical mile = 6080 .27 f t 1 in . of Hr = 2 .540 cm of Hg
1 in . of % = 13 .6 in . of water
HH~~ = mercury at 0°C )
Area
mU = millibar = 1 dyne per sq cm )
1 sq ft = 144 sq in .
1 sq in . = 6 .4516 sq cm Energy
1 circular mil = .7854 sq mi l
(A circular mil is the area of a circle 1 btu = 778 .3 ft-lb
1 mil ( 0,001 inch ) in diameter) 1 btu = 1054 .8 joule s
1 btu = 0 .2930 watt hours
1 bto = 0 .2520 kilo calories
V olume (Liquid)
1 hp hr = 1 .98 x 106 ft-lb
1 on ft = 7 .481 U .S . gal .
1 U .S. gal . = 0 .1337 on ft
Power
1 U .S. gal . = 231 cu in .
1 U .S. gal . = 3 .785 liters
1 hp = 550 ft-lb/sec
1 on ft = 7 .4805 U.S . gal .
1 hp = 745 .7 watts
1 btu/minute = 17.58 watts
Weight
• I lb = 16 o z
Temperature
1 lb = 7000 grains
1 lb = 453 .6 grams
Fahrenheit Scale :
1 kg = 2 .205 lb
1 ton (short) = 2000 lb ice point 32° F, steam point 212°F
Centigrade Scale :
1 U.S. gal . of water (15°C) weighs
ice point 0° C, steam point 100° C
8 .336 lb
Rankine Scale :
1 cu ft water weighs 62 .4 lb (15°C)
R= F+460
1 slug (mass) weighs 32 .2 lb (where
Kelvin Scale :
g = 32 .2) °K=°C+27 3
F=9/5C+32
Veloci ty ° C = 5/9 (° F - 32)
60 mph = 88 ft/aec
1 mph = 1 .467 ft/sec
1 knot = 1 .152 mph
1 ft/sec = 30 . 48 cm/ae c
1 rpm = 0 .1047 radians/a-
0
Acceleration Due to Gravity
go = 32 .17 ft/ sec/sec = 980 . 7 cm/sec/sec
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BNA08758522
H DMSp01659447
MECHANIC'S HANDBOOK
PIPING SYSTEM SYMBOL S •
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•
•
2-4
CONFTDENTTAT, LEVET, T- UNDER PROTECTIVE ORDER ,

BNA0875852 3
California, No. C Y 97-1554
H DMSpO1659448
USEFUL INFORMATION
•
WELDING SYMBOLS
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2- 5
CDNFTDF,1TTAT, T,F,Y'ET, T- UNDER PROTECTIVE ORDER,

BNA0875852 4
United States District Court for the Central District o f
H DMSp01659449
MATHEMATICS
• TRIGONOMETRY
FONC12oN8 of AN ACS7PB Axon

s
The trigonometric functions most often used are the sine, cosine, end tangent. It is
convenient to define the functions of an acute angle in terms of the sides of a right
triangle .
In any right triangle, the sine of either acute angle is equal to the length of the
side opposite that angle divided by the length of the hypotenuse . The cosine of
either acute angle is equal to the length of the side adjacent to that angle divided
by the length of the hypotenuse . The tangent of either acute angle is equal to the
length of the side opposite that angle divided by the length o£ the side adjacent to
that angle .
If A, B, and C are the vert ices of any right triangle (C is the right angle) and a,
b, and c the sides opposite respectively , as shown in the diagram, then
opposite side
sin = din A=g
hypotenuse c
cos =
adjacent side
cos d =b 5053, a
tam= opposite side tanB=b

tamA=b
adjacent side a A
b
•
Note that sin A = cos B ; in other words, the sine of any angle equals the cosine of
its complementary angle .* For example ,
sin 30° = cos (90° - 30°) = cos 60°, and

cos 50° = sin ( 90° - 5o°) = sin 40° .
It is advisable to remember the numerical values of the sines end cosines of the
following angles : (Note that the sine of any angle equals the cosine of its
complementary angle .*)
sin 0° = cos 90° = 0 = 0 .000

sin 30° = cos 60° = 1/2 = 0 .500
sin 45° = cos 45° = i/2 .J = 0 .707
sin 60° = cos 30° = l/2 .J = 0 .866
sin 90° = cos 0 ° = 1 = 1 .00 0
* Two angles are complementary when their sum = 90° . Two angles are supplementary
when their sum = 180° .
•
2- 5

BNAU8758525
H DMSp01659450
M O-lANIC'S HANDBOOK
IAW OF 0051125 RIND IAN OF 822

2
•
These two laws give the relations between the sides and angles of any plane triangle .
In any plane triangle with eagl es A, B, sad C and aides opposite a, b, sad c respec-
tively, the following relations apply :
B
Law of cosines : a2 = b2 + c2 - 2bc coa A
D2 = a2 + c2 - Sac cos B
o = a2 . b2 - tab cos c
sin A sin B _ sin C

Law of sines :
a b c
A -b
510 1 a sin A a sin B= b
or sin B b sin C c sin C c
These two laws apply to any triangle , right-angled or oblique . If angle O as in the
case of angle C in the diagram above is between 90° and 180°, the n
sin 0 = sin (180° = O) aad coa 0 = - cos (180°- O)
hence sin 120° = sin (180° - 120°) = sin 60° = 0 .866
and ens 120° _ - cos (18o° - 120°) _ - ens 60° = - 0.500
Problems and Solutio n •
1 . In the right triangle ABC, given a = 8 and b = 6 . Find the valves of the sine,
cosine, sad tangent of angle A and of angle B .
B
c2 =_J82 +62 = 64+36 = 100=10
sin A = oppositeside _ 8 6
hypotenuse 10 =0 .80 sin 8 = 10 = 0.60
adjacent side __ 6 _ 8
cos A .60 cob B = 10 = 0.80
= hypotenuse 10 - 0
opposite side 8 6 A ! b C
tea A = ad3acent side S ` 1 .33 Lan B = $ = 0 .75
2 . Given a right triangle with one acute angle = 40° and hypotenuse = 400. Find
the other sides and angles .
sin 4o° = 0 '0 and cos 40° _
From the table of nattnal- trigonometrie functions , w find then Cis, 40° a 0 .6428 end
cos to° = 0 .7660 .
a = 400 sin 40° = 400 x 0.6428 = 257 .1
0= 4oo cos 4p° = 400 x 0 .7660 = 306 . 4
•
2- 6
CONEIDENTLAL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA0875852 6
California, Po. CV 97-1554
H DMSp01659451
MATHEMATICS
D
• PROBL31 AND SOLUTIONS CONTINUI
3 . Given c = 8, b = 5, A = 48° . Find side a .
By the law of cosines ,
a2 =b
2 -2bc
+ o cos 48°
= 25 + 64 - 2(5)(8)(0.6691) = 25 + 64 - 53 .5 = 35 .5
a = 35 .5 = 5 .96
4 . Given a = 7, b = 4, C = 130° . Find side c .
By the law of cosines , c2 = a2 + b2 - tab cos 130 °
cos 130° = - cos (180° - 130°) _ - cos 50° _ - 0 .6428
c2 = 49 + 16 - 2(7)(4)(- 0 .6428)
=49+16+36=101 c= 101 =10 . 0
5 . riven A = 64°, B = 71°, b = 40 . Find sides a and c .
c = 18o° - 71° -64°=45°
By the law of sines, s = b c = b

sin A ain BB sin C sin
B
•
_ b sin A = 40 x sin 64° _ 40 x40 x 0 .8 8888
a sia 8 sin 710 - 0 .9455 = 36 . 0
b sin C = 40 x sin 4 40 x 0 .70 1 = 29

C - sia B .9
sin 71° - 0 .945 5
6 . Find, to the nearest degree, (a) the angle whose sine is 0 .3907, (b) the 1
angle whose cosine is 0 .438, ( c) the angle whose tangent is 6 .314 . Ia (a), sin
0 .3907 means " the angle whose sine is 0 .3907•" In the table of natural trigonometric
functions , under Sine, we find that 0 .3907 corresponds to 23° . Therefore :
Sin 1 0 .3907 = 23 °
In (b), cos-1 0 . 438 means " the angle whose cosine is 0.436 .° In the table of natural
trigonometric function, under Cosine , we find that 0 .438 corresponds most nearly to
640 . Therefore :
Cos-1 0 .438 = 64 °
In (c), tan 1 6 . 314 means " the angle whose tangent is 6 .314 ." Is the table of satura .
trigonometric functions , under Tangent , we find that 6.314 corresponds most nearly to
81° . Therefore :
Tan 1 6 .314 = 81°
2-7

BNAU8758527
H DMSp01659452
MECHANIC'S HANDBOOK
FR08LEhn AD0 SOLUTIONS CORTINOED

•
7 . The hypotenuse of a right triangle is 15 and one arm is 9 . Find the other arm
( a) and the acute angles .
a = 152 - 92 = 225 - 81 = 144 = 12
opposite side = 12 = 0
sin A • .8
hypotenuse 1 5
Angle A is that angle whose sine is 0 .8 .
From the table of natural trigonometric functions, we find that the angle whose sine
is 0 .8 lies between 53' and 54° . We interpolate (compute intermedia ry values) as
follows to find the nearest value of the angle whose sine is 0 .8 :
B
Sin 54° - sin 53° = 0.8090 - 0.7986 = 0 .0104
0.8000 - sin 53' = 0 .8000 - 0 .7986 = o.ool4
Then
0
A = 53' + ly = 53° + 0 .13° = 53 .13°
15
But each degree is divided into 60 minutes ( 60 1 ) . Hence
A = 53 .13° = 53' + 0 .13 x 60' = 53'8 '
B = 9o' - 53'8' = 36°52' C

9
•
If A and B are required to the nearest degree, then A = 53°s B = 37'•
2-8

BNA08758528
H DMSp01659453
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0
MECHANIC'S HANDBOOK
LOGARITffi~
•
The logarithm of a number is the exponent, or power, of the base that is require d to
produce that number . For example, since 1000 = 103, 100 = 102, 10 = 101, 1 = 10°,
then the logariths of 1000, 100, 10, 1, to the base 10 are respectively 3, 2, 1, 0 .
The system of logarithms whose base is 10 ( called the con or Briggsian system) is
used in all nto erical computations .
It is obvious that 101 .5377 will give some number greater than 10 (which is 101) but
smaller than 100 (102) . ActuaU .y, 101 .53777 = 34 .49; hence log 34 .49 = 1 .5377• me
digit before the decimal point is the characteristic of the log, and, the decimal
fraction part is the mantissa of the log . Ia the above exempie, the characteristic
is 1 and the mantissa is .5377 •
TSE CHARACTERISTIC
The characteristic is determined by inspection from thearmber itself according to

the following rules :
1 . For a amber greater than 1, the characteristic is positive and is one less
than the mmber of digits befo re the decimal point . For example :
xwber 5297 348 900 34 .8 60 5 .764 3

Characteristic 3 2 2 1 1 0 0
2 . For a number less than 1, the characteristic is aegative and is one more than
the number of zeros bmnediately following the decimal point . The negative
sign of the characteristic is written in either of two ways : (a) above the
characteristic . as 1, 2, etc . ; (b) as 9 . - 10, 8. - 10 etc . Thus the •
characteristic of 0 .3485 is 11 or 9• - 103 of 0 .0513 is 2 or 8 . - 10 .
THE [R42TISSA
The mantissa of the log of a numher is found is tables, ignoring the decimal point of
the comber . Each mantissa in the tables is understood to have a decimal point
preceding it, and the mantissa is always considered positive .
wi mn G LOGARivmti
^
To find the logarithm of a number, use the tables of logarithms which appear in this
section . Suppose , then, it is necessary to find the complete log of the number 728 .
In the table of logarithms, glance down the x column to 72, then horizontally to the
right to column 8 and note the figure 8621 which is the required mantissa Since the
characteristic is 2, log 728 = 2.8621 . (This means that 728 = 102.8621 . )
The mantissa for log 72. 8, for log 7 . 28, for log 0.728, for log 0.0728, etc ., is
.8621, but the characteristics differ . Thus :
1cg 728 = 2.8621 log 0 .728 = 1 .8621 or 9 .8621 - 10

log 72 .8 = 1 .8621 log 0 .0 (26 = 2 .8621 or 8 .8621 - 10
log 7 .28 = 0 .8621 log 0 .00728 = 3 .8621 or 7 .8621 - 10
To find log 46.38, glance down the it column to 46, then horizontally to column 3 and
note the mantissa 6656 . By interpolation the re quired mantissa is .6656 + .0007
_ .6663 . Since the characteristic is 1, log 1, 6 .38 = 1.6663 .
•
2-10
CDNFfDENTTAT, LEVEL T- i7NDE R PROTECTTVF ORi)ER ,

BNA08758530
California, ➢b. CV 97-1554
H DMSp01659455
MATHEMATICS
• - FTND4~ LO1ARP0Th CONTINUE D
log 4638 = 3 .6663 log 0 .4638 = 1.6663 or 9.6663 - 10

log 463 .8 = 2 .6663 log 0 .04638 = 2.6663 or 8 .6663 - to
log 46 .38 = 1 .6663 log 0 .004638 = 3 .6663 or 7 .6663 - to
log 4 .638 = 0 .6663 log 0 .0004638 =x.6663 or 6 .6663 - 10
Interpolation
The mantissa of a comber of nore than three sigiificant figures can be found
approximately by assuming that the msatisaa varies directly as the comber in th e
small interval not tabulated . Thus if N has four digits, sod f is the fourth digit of
N, the mantissa (m) of N i s
where ml is the mantissa corresponding to the first three digits of N, and m2 is the
next larger mantissa in the table .
FINDING ANTII.OGABITB
The antilogarithm is the number cor re sponding to a given logarithm . The "antilog of
3" means the "number whose log is 3" ; that nether is obviously 1000 . Antilogs are
found by reversing the process used in obtaining the logarithm o£ a num ber .
Suppose it is necessary to find the sntilog of 2 .6747 ; i .e ., the number whose log is
• 2 .6747 . The characteristic is 2 and the mantissa is .6747 .
Usiag the table of logarithms, look Sa the body of the tables for the mmtissm 6747 .
In column 2 opposite 47 in the N cols is found mantissa 6739, which corresponds to
mmber 472 and in column 3 is found mantissa 6749 corresponding to comber 473 . Since
the given logarithm was 2 .6747, the required comber must be between 472 and 473. By
interpolation it is found to be 472 .9 . (The characteristic 2 of the logarithm 2 .6747
placed the decimal point . )
USING LOGARITBAS
Since logarithms are exponents , all, properties of exponents are also properties of
logarithms . Thus
1 . The logarithm of the product of two numbers is the sun of their logarithms .
log ab = log a + log b log ( 5280 x 48 ) = log 5280 + log 48
2 . The logarithm of the quotient of two numbers is the logarithm of the numerator
minus the logarithm of the denominator .
log b = log a - log b log = log 536 - log 24 .5
3 . The log of the nth power of a number is a times the log of the numher .
log an = n log a log ( 4 .28)3 = 3 log 4 .28
4 . The log of the nth root of a number is the log of the comber divided by n .
•
log n s = 1 log a log 32 = 2 log 32 log 3 792 = 1 log 792
2-U

BNAU8758531
H DMSp01659456
MECHANIC'S HANDBOOK
Problems and Solution s
1. Find the value of 487 x 2 .45 x 0 .0367 .
Let x = 487 x 2 .45 x 0.0387 log 487 = 2.667 5

log x = log 487 + log 2 .45 + log 0 .0387 log 2 .45 = 0 .3892
= 1.6644 log 0 .0387 = 5.5877 to (add )
x = antilog 1 .6644 = 46 .17 or 46 .2 Log x "11.6644 - 10
or i.6644
~. 3
136
2. Find x =
X5.38
log x = log 136 .3 - log 65 .38 = 0 .3191 log 136 .3 = 2 .1345
x antilog 0 .3191 2 .084 log 65.38 = l (sub )
log x = 0 .3191
3. Find x =
log 1 = 0 = 10.0000 - 10
10 logloogg.o = l.. O2 (sub)
log x = log 1 - log 22 .1 = 8 .6498 - ..
x = antilog 8 .6498 - 10
= 0 .04465 or 0 .0446 (three significant figures )
Adding or subtracting 10 .0000 - 10, 20.0000 - 20, ete ., from any 10-logarithm does
not change its value .
= 17 . x 1.91
4. Find x 0 .283 x 0 .03114
•
log x = (log 17 .5 + log 1 .92) - (log 0 .283 + log 0 .0314 )
log 17 .5 = 1 .2430 log 0 .283 = 9 .4518 - l0

log 1 .92 = 0
~ .2833 ( add) log 0.0314 = 8 .14969~3,0 (add)
1 .5273 17 .9587-20
or 11 .5263 - l0 or 7 .9487 - 10
log 17 .5 a log 1 .92 = 71 .5263 - 10

log 0 .283 + log 0 .0314 = 7 .92487 10 (sub)
leg x = 3 .577 6
x = antilog 3 .5776 = 3781 or 378 0
5 . Find x = (6 .138) 3
log x = 3 (log 6.138) = 3(0.7881) = 2 .3643
x = antilog 2 .3643 = 231 . 4
2
6 . Find x = 514 or (7514)1/
log x = 1/2(log 7514) = 1/2 (3 .8758) = 1 .9379
x = antilog 1 .9379 = 86 .68
7. Find x = 3 0 .0592 or (0 .0592)1/3

log x = l/3(log 0 .0592) = 1/3(8.7723 - l0) = 1/3(28 .7723 - 30) = 9 .5908 - l0
x = antilog 9 .5903 - 10 = 0 .3897 or 0 .39 0
8_ Fired x = ('V 152) 3

log x = 1/2(3 log 152) = 1/2(3 x 2 .1818) = 1/2(6 .5454) = 3 .2727
x = antilog 3 .2727 = 1874 or 1870 (three significant figures ) S
2-12
CONFTDFNTIAI, t,EVEl, 1- i7N1)FR PROTFCTTVF. ORDER ,

BNA0875853 2
H DMSp01659457
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50 F' r w'" V VF' NOOs F+O ~O I + ww N OTN Ot~O
~~Cp ~ 0) Qi
~~pp ;Q ~p p .d + ~ ~p ISQ~0)
' +
CW~ ~
N , N
O ~ . °°
W~0i~ F' N Oi - 1 b NY r
°\ g y ~i W f.i Os b>OO~ ~F'w
so 50
SO 50 SQ SO '05
0 SO '0 '0 ~p ~p ~p p pp 4? to to co w pJ p
~`Q I
OO~O p OA F
~O N r )i WWI m ~p~ wwVNi in NVI CDYF o NV~i ~
O \o
N W au (01-I w 0150 0 0 ~D O~W ~D ~i ~O ~S
V 5 0s. I-1 Os to Fso 03 5n-l-J Ot Ft+-1 H F
• • •
MATHEMATICS
• SLIDE RULE INSTRUCTIONS
These slide rule parts will be referred to in the course of the instruction . Kee p
then in mind .
MJLTIPLICATIO N
To find the product of two numbers , disregard the decimal points . Opposite either
number on the D scale, set the index of the C scale . Push the hairline of the
indicator to the other number on the C scale , and read the answer under the hairline
on the D scale . The decimal point is placed in accordance with a rough calculation .
To multiply 1 .5 x 3 .5 :
Disre gard the decimal point

Set index of the C scale over 15 on the D scale
Mcve hairline to 35 on the C scale
From the hairline read 525 on the D scale
0 \
B
So
' C
D 1 15 1
0 52 5 /
By inspection of the original problem we lmow the answer to be approximately 5 .
The decimal point is placed , and the answer is 5 .25 .
DIVISION
To find the quotient of two numbers, disregard the decimal points ; opposite the
numerator on the D scale set the denominator on the C scale ; opposite the index of
the C scale read the quotient on the D scale . The decimal point is placed by rough
calculation.
A. division is the i verse of multiplioatiom , the came factors apply and the same
scales, C and Dare used .
2_1 5

BNA08758535
H DMSp01659460
MECHANIC'5 HANDBOO K
DIVISION CONTIIVOED
•
To divide 9 by 2 :
Push hairline to 9 on the D scale

Draw 2 of the C scale under the hairline
Opposite index of the C scale read 45 on the D Beale
Place the decimal point - the answer is 4-5-
6
I
I 45 I
I 45
10
PROPORTIONS
Proportions are handled the same as division problems .
To find the proportion 2/3 = x/9
Set 2 on the C scale over 3 on the D scale

Find 9 on the D scale
Opposite 9 on the D scale is the answer, 6, on the C scal e
Note : the same setting wi ll give all other identical proportions, as
4/6, 3/4 .5, 5/7.5, .06/ . 09, etc .
•
TIOMPrR Y
PIE FIGURES
Rectangle
h
Area =bh
2 b
Diagonal d = b2 h
Right Triangle
Area = 2
g
Hypotenuse = c = s + b 2
A°+B°+C° = 180 °
Any Triangle
h
Area = Z
(h is perpendicular to b)
A° + B° + C° = 180°
•
2_16
CDNFTDF,PTTAT, LEVEL I- UNDER PROTECTTVE ORDER ,

BNA0875853 6
H DMSp01659461
MATHEMATICS
• FLA71E FIGURES CO17TINUED
Parallelogram
(opposite sides parallel )
Area = his
(b is perpendicular to b)
A° + B° . C° I D° = 360 °
Trapezoid
(a parallel to b )
Area = a 2 b h
(b is perpendicular to a end b )
Circle
Circumference = IT d
= 27T r
(.?= circumference
diameter
Area = 7Tr2
=7d2
= o.T854d2
IT = 3 .1416
Ell ipse
Area = IT (OA) x (OC )
r (AB) x (CD )
ctor
_ r arc AB
Area 2
= iTr2 AOB
3 0
2-17

BNA0875853 7
United States District Court for the Central Dist ri ct of
H DMSp01659462
MECHANIC'S HANDBOOK
SOLID FIGURES
•
Sphere
3
Volume = 3 7r r3 = 7r
Area = 4 7r r2 = 7 . d2
Cylinder
V.I. = 7f r2 L = 0 .785442 L
Area of cylindrical surface = It dL
C.rliader
Volume = (area base) h
Area of cylindrica l
surface = (perimeter base) h
Cow
Volume (of either) = 3 7l r2 h
Area ( of right cone) = 7T ra
Cube •
Vol. = a3
Diagonal = d = a Y 3
Total area = 6a2
Rectangular Prism
Volume (area of end) c

= a b c
Diagonal = d = e2 + b2 + a
Total area = 2(ab + be + ca)
2-1 8
CONFTDF,1TTAT, LEVET, T- UNDER PROTECTIVE ORDER ,

BNA0875853 8
H DMSp01659463
0 SECTION 3
PIPE, TUBE AND FITTINGS

CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Selection of Pipe and Tubing . . . . . . . . . . . . . . . . . . . . . 3-1
Pipe and Pipe Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Flanges and Flanged Fittings . . . . . . . . . . . . . . . . . . . . . . 3-4
High Pressure Flanged Fittings . . . . . . . . . . . . . . . . . . . . . . 3-4
Tube and Tube Fittings Flared . . . . . . . . . . . . . .. . . . . . . . . 3-5
Superpresoure Tubes and Fittings . . . . . . . . . . . . . . . . . . . . 3- 5
Pipe and Tubing Connections . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Threaded Pipe Connections . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Flanged Pipe Connections . . . . . . . . . . . . . . . . . . . . . . . . . 3- 9
Standard ASA Flanges . . . . . . . . . . . . . . . . . . . . . . . . 3-9
High Pressure Flanges . . . . . . . . . . . . . . . . . . . . . . . 3-9
Tube Fitting s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1
Flared Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
AN and MS Pitting Threads . . . . . . . . . . . . . . . . . . . . . 3-13
AN and MS Fitting Designation . . . . . . . . . . . . . . . . . . . 3-14
RD Fitting Designation . . . . . . . . . . . . . . . . . . . . . . . 3-19
Superpressure Fittings . . . . . . . . . . . . . . . . . . . . . . . 3-20
•
Pipe and Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Piping Expansion and Flexibility. . . . . . . . . . . . . . . . . . . . . 3-20
Tubing Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Pipe Support s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Bend Radii of Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Pipe Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Installation of Flanged Fittings . . . . . . . . . . . . . . . . . . . . . 3-26
Installation of AN and MS Fittings . . . . . . . . . . . . . . . . . . . . 3-26
Superpressure Fitting Installation . . . . . . . . . . . . . . . . . . . . 3-3 3
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Hydrostatic Teats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Identification of Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Vacuum Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Operating Vacuum Pressures and units . . . . . . . . . . . . . . . . . . 3-36
Vacuum Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Piping Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
System Leak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Leak Detection Tests . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
•
1

BNA08758539
H DMSp01659464
•
INTRODUCTION
Pipe and tubing are used for the transfer of fluids between vessels and other equip-
ment . Pipe is distinguished from tubing by the fact that the nominal size refers to
the approximate inside diameter of the pipe . The outside diameter of the various
sizes of pipe is constant, and therefore as pipe wall thickness increases the flow
passage most decrease in size . Pipe sections may be joined by screwed , welded, or
flanged jbints .
Tubing size is specified by outside diameter and comes in various wall thicknesses .
The difficulty of obtaining good quality flares with 0 . 100 inch and heavier walled
stainless steel tubing makes its use impractical . Tubing in use at the Field Labora-
tories varies in size from 1/8" to 2" in diameter . Tubing connections are made with
MS or AN screwed fittings .
SELECTION OF PIPE AND TUB ING
PIPE AND PIPE FITTINGS
Figures 3 .1 and 3 .2 show the allowable pressure for different kinds of pipe . The
selection of pipe for a given installation should be based on these tables . The
design pressure of the system should always be equal to or less than the allowable
pressures shown in the tables .
Pipe fittings are designed to have a bursting strength that is not less than pipe of
the same material and schedule number . Therefore, fittings should be selected with
the same schedule number as the pipe which is to be used for a given service .
• Where a fitting is stamped with a pressure rating by the manufacturer, this pressure
represents the maximum allowable working pressure of the fitting .
3-1
CONFIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER,

BNA08758540
H DMSp01659465
MECHANIC' S HANDBOOK
SEAMLESS UNTI iEADED STAINLESS STEE L' . PIPE
Pipe Schedule N umber end M.rinmm

Pipe Size Allowable Working Pressure, PSI
Nominal O .D . 5 10 40 80 160 %X
1/2 0 .840 2680 3480 4680 6540 $650 15210
3/4 1 .050 2120 2750 3820 5360 7970 12110

1 1 .315 1680 2890 3570 4940 7200 11040
1-1/4 1,660 1320 2260 2940 4110 5520 9000
1-1/2 1 .900 1150 1960 2650 3730 5410 8100

2 2 .375 920 1560 2230 3220 5270 6910
3 3 .500 790 1150 2120 2990 4500 6390

4 4 .500 610 1010 1790 2590 4220 549 0
5 5 .563 650 800 1570 2320 4000 4880
6 6 .625 550 670 1430 2240 3050 4710

8 8 .625 420 570 1260 1980 3720 3580
10 10 .75 410 510 1140 1580 3710 --
12 12,75 430 470 990 1320 3640 --
A1 1evsb1 e working pressure in psi from -325 to 100° F

Allowable stress - 18,750 psi •
ASTM A312 seamless grade TP304 , 321 and 347
Figure 3 .1 Maximum Allowable Working Pressure for Seamless Stainless Steel Pip e
3-2
CONFT)ENTTAT, LEVET, T- UNDER PROTECTIVE ORDER ,

BNA0875854 1
H DMSp01659466
SEAMLESS UNTHREADED CARBON STAINLESS STEEL PIP E
Pipe Schedule Number and Maximum

Pipe Size Allowable Working Pressure, PS I
Nominal O .D . 5 10 40 80 160 XX
1/2 0 .840 330 1100 2260 4050 6070 12300

3/4 1 .050 260 880 1930 3450 6010 10040
1 1 .315 210 1420 2100 3470 5720 9530

1-1/4 1 .660 170 1120 1810 2990 4430 7940
1-1/2 1 .900 150 970 1670 2780 4490 7230
2 2 .375 120 780 1470 2490 4600 6280

3 3 .500 260 640 1640 2550 4120 6090
4 4 .500 200 490 1440 2280 3980 5310
5 5 .563 330 490 1300 2080 3850 4780
6 6 .625 280 410 1210 2060 3750 4660
8 8 .625 210 370 1100 1860 3700 355 0

10 10 .75 250 350 1020 1810 3740 -
12 12.75 300 340 890 1790 3700 --
Allowable working pressure in psi from -325 to 100° F

Allowable stress = 20, 000 ps i
ASTM A53 or A106 Grade B
Figure 3 .2 Maximum Allowable Working Pressure for Seamless Carbon Steel Pipe
0
3-3
CDNFT)F,3TTAT, T,F,VF, T, T - 11NDF. R PROTF.CTTVF. ORDER ,

BNA0875854 2
United States District Court for the Central Distri ct of
H DMSp01659467
MECHANIC'S HANDBOOK
•
PIPE FITTING S
Flanges and Flanged Fitting s
Flanges and flanged fittings are rated for a primary service at a temperature in the
range of 500 to 1125 F. The rating also depends on the type of gasket . The majority
of items at the field laboratories are rated at 100 F service temperature . Ratings
of Standard ASA flanges are shown in Figure 3 .3 .
ASA Primary Service

Pressure Rating, psig Maximum Se rvice Pressure Rating at 100 F, psi g
Carbon Steel and

310, 316, 32 1
and 347 Stainless 304 Stainless
150 275 275
300 720 61 5
400 960 825
600 1440 1235

•
900 2160 1850
1500 3600 3085

2500 6000 5145
NOTE : These are maximum ratings based on usage of beat type gasket .
When ordering weld-neck flanges, the bore corresponding to the

ID of the pipe schedule to be used should be specified .
Figure 3 .3 Pressure Ratings of ASA Standard Steel Flange s
HIGH PRESSURE FIANGED FI TT ING S
For pressures above 6000 psi, Grayloc type flanged fittings should be used .
3-4

BNA08758543
H DMSp01659468
PIPE, TUBE AND FITTING S
TUBE AND TUBE FITTINGS FLARE D

•
Only seamless tubing should be used in the Field Laboratories . Figures 3 . 5 and 3 .6
show the allowable pressures for different kinds of tubing . The selection of tubing
for a given installation should be based on these tables . The design pressure of the
system should always be equal to or less than the allowable pressures shown in the
table . Fittings are designed to be as strong as the strongest tubing of like mate-
ia1 which can be used with the fitting . In the s1 range from 1 /8" through 3/4" it
is possible to make a system leak-tight up to 6000 psi by use of copper seals and
polished sealing surfaces . Sizes 1 " and larger are core difficult to seal . Figure
3 .4 indicates pressures which may be achieved in a carefully assembled system .
Tube Size , Inches Pressure, PS I
1 4500
1-1/2 2000
2 1000
Figure 3 .4 Achievable Pressures in

Carefully Assembled Tube System s
SUPERFAESSURE TUBES AND FITTING S
For pressures above 6000 psi, superpressure tube and fittings should be used .
PIPE AND TUBING CONNECTIONS
THREADED PIPE CONNECTIONS
The normal pipe threads used in the Field Laboratories are :
Standard Pipe Thread s
NPT : American Standard - taper pipe thread s

NPSL : American Standard - straight pipe threads ( for loose fitting mechanical
joints with lockouts )
Dry Seal Pipe Threads
NPTF : American Standard - taper pipe thread (for fuel and oil )
The dry seal threads have a closely controlled truncation of the crest and root of
the threads to minimize spiral leakage in the joint .
3-5

BNA08758544
H DMSp01659469
MECHANIC ' S HANDBOOK
SEAMLESS STAINLESS STEEL TUBIN G

Pall Thiclmesa , Inches •
Tube O .D.
Inches 0 .010 0 .016 0 . 020 0 . 025 0 . 028 0 . 032 0 . 035 0 .042
1/8 2700 4470 5720 7380 8420 9880 11020 13880
3/16 1760 2890 3670 4670 5300 6150 6820 8420
1/4 1310 2130 2700 3420 3860 4470 4930 6050

5/16 1040 1690 2130 2700 3040 3510 3860 4710
3/8 870 1400 1760 2230 2510 2890 3180 3860
1/2 650 1040 1310 165o 1860 2130 2340_ 2840

5/8 550 880 1100 1390 1560 1790 1970 2380
3/4 450 730 920 1150 1290 1490 1630 1970

1 340 .190 680 860 960 1110 1210 1460
1-1/4 270 `623 550 680 770 880 960 1160
1-1/2 230 360 450 570 640 730 Boo 960
1-3/4 190 310 390 490 550 630 680 820
2 170 270 340 430 480 550 600 720
Wall Thickness , Inches

Tube O .D .
Inches 0 .049 0 .058 0 .065 0 .083 0 .095 0 . 109 0 .120
1 8 17040 21610 -- - - - -
3/16 10130 12490 14460 20190 -- -- --
1/4 7210 8780 10070 13670 16330 19750 22710

•
5/16 5590 6770 7720 10330 12220 14570 15570
3/8 4570 5510 6260 8300 9760 11550 13040
1/2 3350 4010 4550 5960 6950 8160 9140
5/8 2800 3360 3790 4960 5760 6730 7520
3/4 2310 2760 3120 4060 4700 5480 6100
1 1710 2040 2300 2980 3440 3990 4430
1-1/4 1360 1630 1820 2350 2710 3140 3480
1-1/2 1130 1340 1510 1940 2240 2590 2870
1-3/4 960 1150 1290 1660 1910 2200 2430
2 840 1000 1120 1440 1660 1910 2120
S - 18,750 PSI
Figure 3 .5 Maximum Allevable Working Pressure in PSI for

Seamless Stainless Steel Fully Annealed Tubing
•
3-6
CDNEIDENTLLL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA0875854 5
H DMSp01659470
•
SEAMLESS ALTMfii1M TUBING (6061T6)
Wa11 Thickness , Inches
Tube O .D .
Inches 0 .010 0 .016 0 .020 0 .025 0 . 028 0 . 032 0 .035 0 .042
1/8 1370 2260 2900 3740 4270 5010 5590 7030
3/16 890 1460 1860 2370 4680 3120 3450 4270
1/4 660 1080 1370 1730 1860 2260 2500 3060
5/16 530 860 1080 1370 1540 1780 1960 2390
3/8 440 710 890 1130 1270 1460 1610 1960
1/2 330 530 660 840 940 1080 1190 1440
5/8 280 450 560 700 790 910 1000 121 0

3/4 230 370 460 580 660 750 830 100 0
1 170 280 350 440 490 560 610 74 0

1-1/4 140 220 280 350 390 450 490 590
1-1/2 110 180 230 290 320 370 410 49 0
1-3/4 100 160 200 250 280 320 350 42 0

2 90 140 170 220 240 280 300 360
Wall Thickness , Inche s

Tube O .D .
Inches 0 .049 0 .058 0 .065 0 .083 6.095 0 .109 0 .120
1/8 8630 10950 -- -- -- -- --

3/16 5130 6330 7330 10230 -- -- -
• 1/4 4450 10010
3650 5100 6930 8280 11510
5/16 2830 3430 3910 5230 6190 7380 8390
3/8 2320 2790 3170 4210 4940 5850 6610
1/2 1670 2030 2300 3020 3520 4130 4630

5/8 1420 1700 1920 2510 2920 3410 3810
3/4 1170 1400 1580 2060 2380 2780 3090
1 870 1040 1170 1510 1740 2020 2250
1-1/4 690 820 920 1190 1370 1590 .1760
1-1/2 570 680 760 990 1130 1310 1450
1-3/4 490 580 650 840 970 1120 1230
2 430 510 570 730 840 970 1070

S = 9,500 PSI
Figure 3 .6 Maximum Allowable Working Pressure in PS I

for Seamless Aluminum Tubing
3- 7
CONFIDENTIAL, LEVEL I- IINDF.R PROTECTIVE ORDER,

BNA0875854 6
H DMSp01659471
MECHANIC IS HANDH008
High Pressure Lena-Ring Connectio n
The as fitti ngs are rated at a maximum working pressure of 10 , 000paig through the 2-
inch sizes, They utilize a lens-ring gasket seal and are available in carbon steel,
low alloy steels, and stainless steel, (304 otainleae fittings are stock items .)
Fittings are available in nominal pipe sizes of 1/2, 3/4, 1, 1-1 /4, 1-1/2, and 2 inches
for usage with, schedule 80, 160 , and double extra-strong pipe .
The high-pressure fittings , while rated at 10,000 psig when installed in a system,
are limited to the pressure rating of the pipe . In no case can the pressure rating
of the system exceed the pressure rating of the pipe .
Special adapters are available to connect systems utilizing the fittings to equipment
or ayatems having tapered pipe threads, ring joint flanges, and weld fitting . .
A typical fitting is shown in Figure 3 .7 .
OODY
IMM
INNER GLAND
SLEEVE LENS-RING NUT
GASKET
Figure 3.7 Lena-Ring Pitting
3-8
CONFIDENTIAL LEVEL I- UNDER PROTECTIVE ORDER ,

BNA087 5 854 7
H D M Sp01659472
PIPE, TUBE AMID FITTING S
•
FLANGED PIPE CONNECTIONS
Standard ABA Flanges
The ASA standard flanges are suitable for use with presaure systems to 6000 psi .
Flanges are avail ble in many types and facings as shown in Figure 3 .9 .
High pressure Flanges
The Grayloe pipe connection consists of two hubs , a seal, and two or three cl amps
depending on the design .
The seal ring combines flexible tapered lips on each side of a rigid rib ; the lips
we the elements that actually seal against the mating hubs . The angle of taper of
the seal lips is slightly less than the mating hub, thereby forming a line to line
seal as soon as the components touch . As the connection is brought together, the
lips deflect (within the elastic limit) changing the line seal to a surface- seal .
Figure 3 .8 shows a typical Grayloc connection .
•
CLAMP
SEAL RIN G
HUB
Figure 3 .8 Typical Grayloc Connection
3-9
CONFID ENTIAL LEVEL I- UNDER PROTECTIVE ORDER,

BNA0875854 8
H DMSp01659473
MECHANIC'S HAMMOK
Figure 3 .9 American Standard Flanges
0
3-1Q
CDNPIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA08758549
California, No. Cl 97-1554
H DMSp01659474
PIPE, TUBE AND FITT INGS
•
TUBE FITTINGS
Flared Fittings
The AN/MS fitting consists of three pieces : a coupling nut (AN818), a sleeve
(M820819 ) , and a connector . The sealing occurs between the wee of the fitting and
the inside or the flare on the tubing . AN819D aluminum sleeves are not used at the
field laboratories since the aluminum work hardens and tends to crack . See Figure
3 .10 .
AND specifications and AN parts are in many instances being replaced by ME specifica-
tions and parts . In some cases the AN and MS parts are interchangeable . Check the
Rocketdyne Standards Manual for applicable specifications .
Stainless steel and AN/MS fittings are structurally limited to the following pres-
sures ( based on a 4 :1 safety factor) :
1 . 1/8" through 7/8" size - 6000 psi
2. 1" through 1-1/4" size - 5000 psi
3. 1-1/2" through 2" size - 4500 ps i
Tubing shall be flared to conform to AN or MS standards and checked accordingly for

craeke, burrs , sbarp edge . and ooncentricity .
Where possible , tube and fitting material shall be alike to reduce the possibility
of scratching , distortion , and galvanic corrosion associated with the use of dis-
similar materials .
•
Where flares are damaged or otherwise defective ; the flare shall be removed and a
new flare made . Tubing shall not be reflsred .
3-1 1

BNA08758550
H DMSp01659475
SLEEVE SUPPORTS
TUBE AND PREVENTS
WIPING OF NU T
ON FLARE
OUTER EDGE
OF FLARE
MUST PASS
FLARE PER INNER EDGE
AND 10061 OR OF SLEEVE
MS 33584 BUT NOT
EXCEED
OUTER EDGE
•
III~~~HIIIIIIIIII~~ ` .
Figure 3 .10 3 Piece AN Flared Tube Fitting Per M33656
•
3-12

BNA08758551
H DMSp01659476
PIPES, TUBES, AND FITTIISUS
•
AN and MS Fittings Threads
AN and MS fittings employ two types of thread, the AN or MS straight thread which
uses the American National Fine Thread Series and 12 thread series ; and the American
Standard Taper Pipe Thread ( NPT) . The straight thread is always used for tubing
fittings and often on other fittings . The NPT is used on fittings other than tubing
fittings .
The two thread types are not identical , and though some of the sizes appear to be
interchangeable , joining the two will form an imperfect joint . See Figure 3 .11 .
Tubing AD, inch Fitting Dasn No . Fitting Thread Size*
1/8 2 5/16 - 24 UNF - 3B

3/16 3 3/8 - 24 UNF - 3B
1/4 4 7/16 - 20 UNF - 38

5/16 5 1/2 - 20 UNF - 3 B
3/8 6 9/16 - 18 UNF - 3B

1/2 8 3/4 - 16 UNF - 3B
5/8 10 7/8 - 14 UNF - 3B

3/4 12 1-1/16 - 12 UN - 3B
• 1 16 1-5/16 - 12 UN - 38
1-1/4 20 1-5/8 - 12 N - 3B
1-1/2 24 1-7/8 - 12 N - 3B
1-3/4 28 2-1/4 - 12 UN - 3B
2 32 2-1/2 - 12 UN - 3B
*Diameter - Threads per inch - Thread typ e
Figure 3 .11 AN Fittings , Straight Thread Sizes

(Per MIL-8-7742)
3-1 3
CONFTDE1TTAT, LEVET, T- UNDER PROTECTIVE ORDER ,

BNA0875855 2
H DMSp01659477
)WEEANICIS HANDBOOK
AM soot MS Fitting Designation

•
Pitting numbers are made up of the basic number followed by a dash number . See
Figure 3 .13 .
The basic number indicates the type of fitting.
Dash numbers indicate the size of fitting .
Fittings are made of four materials : steel, aluminum alloy, copper-

base alloys , and corrosion-resistant steel . When the fitting is
obtainable in all four materials :
No letter with dash number indicates steel .

The letter "D" with dash number indicates aluminum alloy .
The letter " B" with dash number indicates copper alloy .
The letter "Cl- with dash number indicates corrosion - resistant steel .
When the fitting is obtainable in steel or aluminum alloy only .
No letter with dash number indicates steel .

The letter "IF' with dash number indicates aluminum alloy .
When the fitting is obtainable in copper alloy or aluminum only ;
No letter with dash number indicates copper alloy .

The letter "D" with dash number indicates aluminum alloy .
AN fittings are colored for identification as shown in Figure 3 .12 .
Material Color Pressure Limi t
Steel (Carbon ) Black 3000 psi

•
Aluminum Alloy Blue 3000 psi
Corrosion-Resistant Steel Natural 6000 psi
Copper Base Alloys Natural Cadmium Plate ( Not stocked )
Fittings have two types of connector thread ends , straight thread ends, and pipe
thread ends .
Figure 3 .12 Tabs Fitting Color Code and Pressure Rating
¢1 4 40
1
CONFIDENTLAL LEVEL I - UNDER PROTECTIVE ORDER ,
BNA087585 5 3
Californ ia, No. CV 97-1554
H D M Sp01659478
PIPE, TUBE AND FITPING S
•
AN 783 AN 784 AN 804
MS24388 MS24389 M52439 0
~ I
TEE-STR AIGHT THREAD TEE-STRAIGHT THREAD TEE
AN 806 AN 81 4 AN 81 5
MS24391 MS24392
' 4`071
PLUG PLUG AND BLEEDER UNION V

AA7 6 0I
AN 816 AN 818 MS2081 9

•
NIPPLE COUPLING NUT COUPLI NG SLEEV E
MS20823
AN 821 M3 20822
MS2440I
ELBOW ELBOW ELBOW

Zoo -
Figure 3.13 Tube Fittings (Sheet 1 of 4 )

•
3-1 5

BNA08758554
H DMSp01659479
MECHANIC'S HANDBOOK
AN 824 MS20825 MS20826 is

MS24402
nl
TEE TEE TE E
,WAN 827
AN 832 , AN 833
MS24393 MS24394
Eg ~s,. ~ ~ I
' 1Ni~MYr~ _ ~
_
UNION ELBOW
CROSS
AN 1134 AN 837 AN 893

MS24395 MS24396 MS24397
•
j CE
REDUCE R
-f TEE ELBOW BUSHIN THREAD
AN 894 AN 910 AN 91 1
NS24398
„I
I~
EXPANDER
BUSF4NG-STRAIGHT THREAD COU PLING--PIPE THREAD NIPPLE
PIPE THREA D
Figure 3 .13 Tube Fittings (Sbeet 2 of 4 )
•
3-16

BNA08758555
California, No. C`' 97-1554
H DMSp01659480
PIPE, TUBE ACID FITTD)G S
AN 91 6
Ar
ELBOW-PIPE THREAD
AN 924
• M82440 0
CROSS -- PIPE THREAD NUT
AN 937
CROSS- STRAIGHT THREA D
Figure 3 . 13 Tube Fittings (Sheet 3 of 4)
3-1 7

BNA08758556
H DMSp01659481
AN939 •
ELBOW - STRAIGHT THREAD
TRTX-S AN 6289 NAS 424
REDUCER
NUT COUPLING
STRAIGHT THREAD •
AN 742
(O
D
CLAMP
Figure 3 .13 Tube Fittings (Sheet 4 of 4)
•
3-18

BNA087585 5 7
H D M Sp01659482
PIPE , TIRE AND FITTINGS
•
RD Fitting Designation
Rocketdyne has found it necessary to design a number of fittings which deviate in one
way or another from the AN or 115 Standard counterpart . The 'deviation might be that
of :
1 . Finish
2 . Size
3 . Configuration
4 . Addition of lockwire hole s
5. Lubrication (Dry Lobed)
6 . Other deviation s
The Rocketdyae design numbering system for fittings is shown in Figure 3 .14 . For
further information refer to the Rocketdyne Standards Manual .
BD 000-0000-0000
L END CONNECTIONS
0 1 Indicates type and size
02 of threads . (These numbers
03 are not indicative of the
04 same thread type and size
Etc . when used with a different
• part number . )
MATERIAL
OOCD . S
01 Aluminum Alloy
02 Stee l
'BASIC PART NUMBER

2008 Adapter--straigh t
2009 Adapter -90 degree elbow
2010 Unio n
Etc .
SEVERAL CATEGORY
111 Bolts
112 Screws
273 Fittings
Etc,
STANDARD
BD-Rocketdyne Design
Figure 3 .14 Boeketdyne Fittings Design Numbering System
3-1 9

BNAU8758558
H DMSp01659483
MECHANIC'S HANDBOOK
Superpressure Fittings
•
Smperpressure , union-type fittings consist of four parts : a male tube , a female con-
ueotioe in valve or fitting , a gland nut, aad en toner sleeve . The male tube has a
59 degree conical seating surface that mates with a corresponding 60 degree female
conical seat in the body . The male tube and loose sleeve have left -hmd threads ;
the gland nut and opening in the valve or fitting body have right-hand threads . As
the gland out is slipped over the al . eeve and screwed into the opening is the body,
the sleeve is tightened on the tubing at the same time as the conical seating sur-
faces are sealed . A typical fitting is shown in Figure 3,15 .
BODY
Figure 3 .15 Superpressure Fitting •
PIPE AND TUBING INSTALLATION
GH>Z~AL
Inatallatios of pipe snd tubing should be dune in a neat and orderly manner . Groupe
of parallel tubes should be aligned, and uniformly spaced . Where possible a common
rack or strut should be provided to support the entire group of tubes . Similarly,
pipe should be run in an economical manner between the start and finish point . Where
several pipes are rua in the same location, they should be parallel and at the same
elevation so that a common pipe rack may be used to support them . It is not neces-
sarily an economy to run diagonal lines between two points, since the layout must
allow for piping expansion and contraction . By judiciova layout of a system, it . is
usually possible to : provide flexibility without the need of flexible hose or ex-
pension joiots, minimize connections and fittings, provide heat shielding by use of
structural members end optimize drainage of the system .
PIPING EXPANSION AND FLEXIBILITY
When a piping system expands (or contracts ) under the influence of a change in tem-
perature of the contained fluid or surrounding atmosphere, each individual run in-
creases (or decreases ) in length . If only one point of the line were kept in a fixed
position when the line is expending , growth radially outward from this point could
take place with perfect freedom and not stresses would be set up . Actually , however,
piping systems have more than one fixation ; they are nearly always restrained a t
•
3-10

BNA0875855 9
Califomia, No. CV 97-1554
H D M Sp01659484
PIPE, TUBE AND FITT fl S
• their terminal points by the equipment they connect, and often also at intermediate
points by anchors , guides, stops , rigid hangers or way braces ; these restraints de-
velop resistance to expansion and thereby put the line under stress and cause it to
deform .
C ryogenic lines may be cooled to temperatures as low as -423 ° F when subjected to

liquid hydrogen . Figure 3 . 16 shows the contraction that would occur in a 10 foot
length of metal line when cooled from 70° to -423° F .
Material Contraction , Inche s

Stainless Steel 0 .3 7
Copper 0 .4
Aluminum 0 .4 9
Figure 3 .16 Contraction of 10 Foot Length of Tubing at -423° F
Longer lines will have a proportionately greater contraction . If the line is not
flexible enough to provide this contraction , the material will be permanently dis-
torted , and may possibly fail . Every installation must be evaluated on the basis of
its normal service . If the line is heated, it will expand rather than contract .
Figure 3 .17 shows some typical Field Laboratory service conditions , and the expansion
or contraction that would be expected .
Inche s
Type System Contraction Expansion

5000 psi Gm2 Blowdown line 0. 1
•
Liquid O xygen 0 .3 4
Compressor Discharge ( Carbon Steel) 0.2
Hot GN2 at 350° F ( CRES) 0.3
Figure 3 .17 Estimated Expansion or Contraction of a 10 Foot Length of Pip e
TUBING SOPPOIIT S
Reeommended maximum spacing for rigid line tubing assemblies is given in Figure 3 .18 .
Tubing supports in a test area , or where subjected to vibration , should be placed
adjacent to fitting such as unions , tees , etc . in addition to the spacing given in
Figure 3 .18 . Supports should be placed as close to bends as possible .
Valves and similar components such are not supplied with mounting holes may be sup-
ported by the tubing, provided a tube support is placed as close as possible on each
side of the component.
Straight tubes should not be used between two rigid coactions , because of the high
stresses imposed when the tube expands or contracts . Supports must be located to
allow for expansion and contraction .
•
3-2 1

BNA0875856 0
H DMSp01659485
Tubing assemblies must be supported to prevent undesirable stresses and consequent

vesieuing of the eystem. In addition , proper support minimizes the danger of recoil •
and line whip in the event of tubing failure caused by excessive pressure .
Where tubes of different diameters are connected , average spacing may be used . Sup-
ports should be placed as close to each side of valves , regulators , etc, as practical .
Overhang should be minimized by placing supports as close to beads as conditions viii
allow .
Located in Test Area and/o r Not is Test Area

Subject to Vibration, inch No Vibration, inch
Tube
OD, inch Aluminum Stainless Steel Aluminum Stainless Stee l
1/4 13-1/2 16 48 48
5/16 15 18 48 48
3/8 16- 1/2 20 48 48
1/2 19 23 60 72
5/8 22 25-1/2 60 72
3/4 24 27-1/2 60 72
1 26-1/2 30 84 108
1-1/4 28-1/2 31-1/2 84 108
1-1/2 31 34 84 108
•
2 36 38 84 108
Figure 3 .16 Haximmo Rigid Tubing Support Spacing
•
3-22
CDNEIDENTL&L LEVEL I - UNDER PROTECTIVE ORDER ,

BNA0875856 1
H DMSp01659486
•
PIPE SUPPORT S
Supports must be fabricated and assembled to permit the free movement of piping
caused by thermal expansion and contraction or by other causes .
Spacing of supports must prevent excessive sag, bending and shear stresses in the
piping, with special c sideratiou given to those piping sectiooe where flanges,
valves, etc, impose concentrated loads . Where calculations are not made suggested
spacing of hangers or supports for piping operating at 100° F and lower are gives
in Figure 3 .19 .
MSXII4IH SPAN (PIPE AT 100° F )
Nominal Pipe Stainless and Aluminu m

Size ( Inches ) Carbon Steel Alloys Coppe r
1 S 8 5
1-1/2 9 9 6
2 10 10 6
2-1/2 12 11 7
3 13 12 S
3-1/2 12, 13 8
4 15 14 9
5 16 15 10
• 16 to
6 18
8 19 17 11
10 22 18 13
12 23 20 14
Figure 3 .19 Maximum Pipe Support Spacing
3-23

BNAU8758562
H DMSp01659487
MECHANIC ' S BA100BOO K
BFND RADII OF TUBING •
Tubing installations requiring bends must he accomplished with minimum distortion

sad constriction of the tubing. A satisfactory bend is one which decreases tubing
00 less than 6 percent . Figure 3 . 20 a table of minimum bend radii will yield satis-
factory bends when accomplished with the proper tools and methods . Attempts at tube
bending with improper tools or by incorrect methods will result in constricted
sections of bend with a reduction of fluid flow . Such incorrectly bent sections
should not be installed .
Minimum Bend Radii for Stainless Steel sad Alumin um Alloy Tubin g
(All measurements in inches )
Tube OB Wall Thickness Inside Bend Radii Radii to Center of Tube
3/16 any 5/8 23/32

-- --7/8 .
1/4 any .- -"3/4
5/16 any 3/t. T32
3/8 Through 0 .022 1-1/2 1-11/16
over 0 .022 1 1-3/16
1/2 Through 0 .028 1-3/4 2
over 0 .028 1-1/2 1-3/4
5/8 Through 0 .028 2-1/2 2-13/16
over 0 .028 1-3/4 2-1/16
3/4 Through 0 .028 3 3-3/8

over 0 .028 2-1/2 2-7/8
•
7/8 Through 0 .035 3-1 /4 3-11/16
over 0 .035 2-3/4 3-31 16
1 Through 0 .035 3-1/2 4
over 0.035 3 3-1/2
1-1/8 Through 0.035 4 4-9/1 6

over 0 .035 3-1/4 3-13/16
1-1/4 Through 0 .035 4-1/2 5-1/8
over 0 .035 3-1/2 4-1/8
1-1/2 Through 0 .035 6
over 0.035 4 4-3/4a
-~
1-3/4 Through 0.035 7 7-7/8
over 0.035 5 5-7/8
.2 Through 0.035 7 8
over 0.035 6 7
2-1/2 Through 0.049 9 10-1/4
over 0.049 7 8-1/4
3 Through 0 .049 11 12-1/2

over 0.049 9 10-1/2
4 Through 0.065 12 14
over 0.065 10 12
Figure 3 .20 Minimum Tube Heed Radi i
3-24

BNA08758563
California, No. CY 97-1554
H DMSp01659488
•
PIPE TEREADS
The most commonly used pipe thread in this count ry is the American Standard Taper
Pipe Thread , also known as National Pipe Thread (NPT) .
A variation of the NPT is the Dry seal thread used on pipe threaded AN and MS parts .
These threads are eomPletely interchangeable and will mate without interference .
Dryseal pipe threads NPTF ) (the F indicates fuel ) permit less leakage than
Americ an Standard Taper Pipe Thread (NPT)_ However , either can be made to seal with
the other . A sealing compound must be need when either of the threads is not D ry seal .
Thread Assembl y
It is advisable to lubricate all pipe threads before assembly . When any tapered
threads except Dryseal pipe threads are mated, a sealer or a thread compound must be
used . The thread compound must be compatible with the fluid in the line .
It is important that the threads of both parts of screwed pipe joints be thoroughly
cle an ed before they are joined . The lubrican t reduces the friction , allowing the two
parts to be pulled up further and resulting in a more effective pipe joint .
Apply lubrican t in streak across the male threads only . See Figure 3 .21 .
Figure 3 .21 Apply Lubric an t in Streak Across

Male Threads Onl y
3-25

BNA08758564
H DMSp01659489
MECHANIC'S BLNDBOOE
INSTALLATION OF FLANGID FITTINGS •
A wide variety of pipe flanges and couplings are used at the Field Laboratories .
Care must be used to assure that the flanges match the facing of the equipment to
which it is connected , and to assure that the proper gasket is used .
Flange faces should mate evenly and should not be bent -to-match with the flange bolts.
The flange bolta can cause distortion and permanent damage to the flange if they are
not loaded evenly.
Flat face flanges and full gaskets suet be used with cast iron pump flanges to pre-
vent cracking of the pump flange .
Flange facing should be protected during installation to prevent scratching and pos-
sible leakage .
I SIALLLA TION OF AN AND MS FITTING S
It is absolutely necessary that open ends of tubing and fittings be kept capped until
they are connected into the system . If they are disconnected at any time , they most
be capped at once . Expensive units can become contaminated or permanently damaged by
dirt and chips if this is not done .
Immediately prior to installation of fittings , lubricate the sleeve bearing outer

surface snd the male threads of fittings by applying a thin coating of prescribed
compound. Do not allow the compound to coat the inside of the tube or flare . See
Figure 3 .22 •
Flace the tube in position , making certain that it is nut scratched during installa-
tion, and see that the tube flares or tube ends meet the fittings squarely and fully .
Never use an AN not to draw the tube to the fitting as the flare or sleeve might be •
opus off or damaged .
Using fingers only, start the nut on the fitting and turn it until flares or sleeves
are firmly seated . Never use a wreaoh until the nut is finger-tight .
After the nut is firmly in place , tighten the AN nut with a torque wrench , using the
valves shown in the torque tables . Use a second wrench en the hex of the body to
eouaterast the torque of the wroaeb oa the ant . See Figure 3 .23 through 3 .27 .
If the fitting leaks, correct the defect if possible , and replace if necessary .
NOTB : Do not tighten the AN or MS nut over the maximum torque recommended .
Never attempt leak correction with pressure in the system .
3-2 6
CDNFfDF.nTTAT, T,FXET, T- i7NDF. R PROTF.CTTVF. ORDFR ,

BNA0875856 5
H DMSp01659490
PIPES, TUBE, AND FITTINGS
FLARE D
Figure 3 . 22 Installation of Tube Fitting s
•
3-2 7

BNA0875856 6
H DMSp01659491
50CE,1NIC ' S FfANDTOO
Fitting or plug with end Coat male threads sad

er 5533656 style E gasket sparingly with
(Style E bas a wide hex . I thread compound .
Some fittings use a
narrow her which will
not support the gasket. )
Gasket called out on

drawing
(14s25778 to hydrsulio
and pneumatic use) I
Screw the fitting or plug

into the boss until it
contacts the boss sur-
face as shown .
•
STEP 2
Figure 3 .23 Iaatallation of 5533656 Style E Fitting

End Into A5510050 Bos s
3-2 •
BNA0875856 7
H D M Sp01659492
PIPE, TOBE AND FI TT ING S
Coat male threads, 14528777 leather ring

r MS28774 teflon ring, and MS28778 gee-
ket sparingly with applicable thread
compound and assemble as shown in step 1 .
If the leather ring is used, have the
smooth ( hair side) against the gasket .
14528777 Leather ring Work the 14828777 leather ring or MS28774
or 14S28774 teflo n teflon ring into the counterbore of the
ring AN6289 out ; then turn the AE6289 nut
MS28778 Gaske t down until the 14828778 gasket is pushed
firmly against the lower threaded section
Groove of the fitting .
STEP 1
Fitting
Install the fitting into the AND10050
boss and, at the same time , keep the
AN6289 out turning with the fitting until
1146289 Nu t the MS28778 gasket contacts the AND10050
boon, as shown in step 2 . This poin t
MS28778 Gaske t can be determined by a sudden increase
in torque . With the fitting in this
position , put a wrench on the AN6289
AND10050 Bos s nut to keep it from turning and, at the
same time , turn the fitting in 1-1/2
turns . Position the fitting by turning
• it in not more than one additional turn .
STF,P 2
Hold fitting and turn AN6289 nut down

tightly against AND10050 boss, as shown
in step 3 . Slight extrusion of the
14528777 leather ring or 14826774 teflon
ring is not detrimental at the initial
installation, but they shall not be
reused at any re-installation of the
fitting in the boss .
Step 3
Figure 3 .24 Installation of 14S33657 Fitting End Into AND10050

Boss in Hydraulic and Pneumatic System s
3-29

BNAU8758568
H DMSp01659493
MBCHANIC ' S HANDBOOK
Assemble AN924 nut on fitting end and

run all the way back to clear fitting
groove . Coat male threads and gasket
sparingly with thread compound,
Assemble gasket in groove . Hold gasket
firmly against the top threaded
section of the fitting and non not
down until it contacts the gasket.
Step 1
Assemble the fitting into the

AND10050 boss and, at the same time,
keep the AN924 not turning with the
fitting until the gasket contacts the
boss . The point can be determined by
a sudden increase in resistance .
•
Step 2
Continue .to screw the fitting into the

boss for another 1/4 turn . Keep the
AN924 nut turning with the fitting to
prevent cutting the gasket with the
fitting thread . Position the fitting
by turning the fitting and nut by not
more than one additional turn . Hold
fitting end turn AN924 nut down tightly
against the AND10050 boss . Torque to
proper value .
Step 3
Figure 3 .25 Installation of 11S33657 Fitting Hod Into AND10050 Boss

in Other Than Hydraulic and Pneumatic Systems
3-30 •

BNA08758569
H DMSp01659494
Bulkhead 316 thick or les s

For thin bulkheads use a thin washer
AN901 Washe r here to avoid interferenc e
Style S Shoulde r A11924 Nut

milar to AN83 3
Elbow or 804 Te e
Fitting end per
5s53657 style S
Shoulder similar Bulkhead over 316 thick

to AN833 Elbow
.510924 Nu t
Fitting end per

N277657 style $
• u~~uuu
Requires 511901 Washer
for use in pressurize d
bulkhead
Bulkhead
Style E Shoulder
similar to A11832
AN924 Nut
Union
Fitting end per

I I 91S33657 style E
Shoulder similar
to AN783 Tee
Figure 3 .26 Installation of MS33657 Fitting Ends Through

Bulkheads or Brackets
3-3 1

BNA08758570
California, 1o. CV 97-1554
H DMSp01659495
Bulkhead Hole Diameter

Fitting AN92 4
Single Sheet Multiple Sheet
Thread A 5901 Washer Nu t
Tube Size Diameter Fraction Decimal Fraction Decimal ( . 0508 Thick) Size
1/4 7/16 15/32 .469 1/2 .500 -44 -412

5/16 1/2 17/32 .531 9/16 .562 -5A -5D
3/8 9/16 19/32 .594 5/s .625 -6A -612
1/2 3/4 25/32 .781 13/16 .812 -BA -SD
5/8 7/8 29/32 .906 15/16 .931e -10A -1OD
3/4 1-1/16 1-3/32 1 .094 1-1/8 1 .125 -12A -1212
1 1-5/16 1-11/32 1 .344 1-3/9 1 .375 -16A -16D
1-1/4 1-5/8 1-21/32 1 .656 1-11/16 1 .688 -20A -20D
NOTE : Use AN901 Aural washers (maximum temperature 400 F ) for both pressure end
nonpressure applications . The 2(17 washer is used for temperatures over
400 F through 1200 F ( nenpressure ) . Dural washers are used on the not side
•
if bulkhead thicknesses Are below the minimum thickness specified. In a
pressure application , these washers must be replaced when the fitting is
removed .
Figure 3.27 Hole Diameters for Bulkhead Fittings
•
3-32
CONFTDTNTTAI T,TVPT,1- ITN)E10 PTOOTPCTWE ORi)P12 ,

BNA0875857 1
H DMSp01659496
•
SUPERPRESSURE FITTING INSTALLATION
Supplier - furnished tools shall be used to prepare the tube end for fitting into the
cmriunoinevolvcs end fittings (1/4 - 9/16- inch size . Preparation of tubing con-
sists of coming and threading operations .
Cone superpressure tubing as follows :
Care should be taken to avoid nicking or scratching the tubing during coning and
threading operations . The pressure rating of the tubing may be greatly affected if
tubing is nicked or scratched .
1 . Clamp tubing in a smooth - jaw machinist ' s vise, with. soft material or wood
over jaws .
2 . Unscrew clamping ring of forming tool to rear position .
3 . Slide forming tool over tubing until tubing sod butts against cutting edge .
4 . Tighten setscrew to hold forming tool firmly on tubing . See Figure 3 .28 .
CLAMPING
RIN G
Tl1BING
•
LL)
GrrTING
EDGE
sE75Cfa W
HANDL E
Figure 3 .28 Forming Tool for Superpressure Tubing
3-3 3

BNAU8758572
H DMSp01659497
5 . Lubricate tubing -cutting edge junction . •

NOTE
Cutting edge should be lubricated freely and frequently with an

approved culpbor -base cutting oil during coning operation .
6 . Rotate crank at approximately one turn per second while rotating feed handle
clockwise until tubing has attained the required cone tip diameter ( figure
3 .29) .
NOTE
Cutting edge will last longer when a uniform , light feed, just heavy
enough to keep the cutting edge cutting continuously , is employed .
If to light a cut is taken , surface will work-harden and make a
smooth cut difficult ; too heavy a cut may break the cutting edge .
7 . Bold feed handle still at end of cut and make several turns with crank to
ensure smooth finish on cone .
8 . Loosen setscrew and remove forming tool from tubing .
Assemble threading tool ( figure 3 .30) as follows :
1 . Select proper size tubing guide bushing for tubing to be threaded, and
insert it into threading tool, aligning curved slot with retaining screw
hole .
2 . Secure tubing guide bushing with bushing retaining screw .
3 . Partially unscrew three die retaining screws, and insert appropriate button
•
die, adjusted for two- thirds of required thread depth .
NOTE
The surface on which the thread size is marked shall face the
guide bushing end of the threading tool .
4 . Align button die until two conical recesses and slot of die line up with
three die retaining screws .
5. Tighten die retaining screws .
Thread auparpraaaura tubing an follows :
1 . Slide threading tool (guide bushing end first ) over rigidly held coned
tubing .
2 . Lubricate tubing and die freely with an approved sulphur-base cutting oil .
3 . Roto.te threadiag tool eosnterclookwiee approximately 1-1/2 to 2 revolutions ;

back off 30 degrees , and lubricate freely . Continue this procedure until
required length of thread ( figure 3. 29) is attained .
4 . Rotate threading tool clockwise until die disengages from tubing , and remove
tool from tubing .
5 . Aemovebutton die from threading tool and adjuat for full thread depth, or
replace with different die set for full thread depth .
6 . Install button die is threading tool and repeat steps 1 through 4 .

•
3-34

BNA08758573
H DMSp01659498
•
Length .f Thread Diamete r
(Tip oc Cone to of
DD and ID of Left-Hand End of Thread ) Cone Tip
Tubing ( Inch) Thread ( Inch ) (Inch)
1/4 o 1/16 1/4-28 9/16 1/8
1/4 x 3/32 1/4-28 9/16 1/8

3/8 x 1/8 3/8-24 3/4 7/32
9/16 a 3/16 9/16-18 15/16 9/32
9/16 x 5/16 9/16-18 15/16 11/32
Figure 3 .29 Superpressure Tubing Thread s
Figure 3 .30 Threading T00 1 for Superpresaure Tubing
3-3 5

BNAU8758574
H DMSp01659499
![ECHANIC ' S RANDBOOS
CLEANING
•
Prior to the installation of pipe end tubing assemblies into a system, the assemblie s
shall be thoroughly cleaned and dried free from all foreign material , chips, and
rust .
After cleaning, all fittings and the open ends of tubing shall be capped or sealed
with a suitable plug or material . Tubing and fittings shall remain capped until
immediately prior to being connected into the system .
HYD1a0sTATIC TESTS
Following assembly of the piping or tubing system , the system should be given a
hydrostatic test . Hydrostatic tests of tubing systems without welded parts is not
required .
IDENTIFICATION OF SYSTEMS
Piping and tubing systems shall be identified with color coded tape in accordance
with existing procedures . These tapes shall indicate :
1 . The name of the material in the system (e .g . LOX, NTO, GN2, etc .)
2 . Direction of flow
3 . Pressure
VACEIM PIPIN G •
GENE$AL
Vacuum systems which provide a condition of almost complete lack of atmosphere are
videly used in providing vacuum insulation and providing enviroumental chambers for
space simulation . Because of the special and sometimes ertreme requirements of
vacuum system components a brief coverage is made .
OPERATING VACUUM PRESSURES AMID UNITS
The most fsmillar unit of pressure or vacuum is the mllllmeter of mercury (mm of Hg) ;
however it is now called the torr . Some of the commonly used vacuum pressure units
ere liated .ia Figure 3 .31 .
Altitude torr Microns of Hg

Atmssphere ( Feet ) PSIA (mm of Hg) (µ )
1 0 14 .7 760 760,00 0
0 .068 6 . 1 r 10 4 1 52 52,000
1 .32 x 10-3 1 .5x 105 1 .93 x102 1 1,00 0
1 .32 x 10-6 3 .1 X 10 5 1 .93 x 10-5 10'3 1
1 .32 x 10-9 9 . 2 10 5 1 . 93 : 10-8 10-6 10'3
Figure 3 .31 Vacuum Conversion Units
•
3-36
CDNPIDENTL&L LEVEL I . UNDER PROTECTIVE ORDER ,

BNA08758575
H DMSp01659500
• Insulation systems to be effective must operate in the following ranges :
1 . Powder-Vacuum 10-2 torr
2 . Super Insulation 10-° tou r
3 . Hard Vacuum 10-3 to 10-6 tor n
The degree of vacuum attainable depends on the type of pump used . Ranges of pumps
1 . Mechanical 10-3 to 10-4 torr
2 . Diffusion (backed below 10-3 torr

by mechanical )
VACUUM SYSTEMS
In vacuum systems Figure 3.32 there are three important factors to consider :
1 . The importance of providing lines which are as short and large in diameter
as possible . As a rule the system pressure drop should not exceed 20 per-
cent of the desired operating pressure . Line size becomes extremely im-
portant at pressures in the 1 to 10-3 torr since gas flow which is viscous
at pressures above 1 torr changes to a diffusion type flow at pressures
below 10-3 torr . In this range line sizes must be large to get any pumping
speed at all .
2 . The desirability of incorporating into the system sufficient vacuum tight

valve and gage connections to permit "trouble shooting " analysis when
• operating pressure cannot be maintained . In this respect vacuum gages
should be placed where they will measure the systems pressure rather than
the pressure near the pump . It is also possible to get a higher pressure
than true system pressure if a vacuum gage is located in a branch line near
a pin hole leak .
3 . The necessity of eliminating leaks to an extent far beyond the requirements

of ordinary pipe . To the novice, a system that is not scrupulously clean
may appear to leek because it may take considerable time to pump out oil or
dirt (with a relatively high vapor pressure ) from construction .
PIPING COMPONENTS
Pipe
Nearly all the common structural metals may be used for vacuum lines . Stainless and
carbon steel and aluminum are widely used . Ordinary carbon steel is not often used
in vacuum insulation linen where the part becomes cold (low temperature embrittle-
ment) ; but it is often used for the outer room temperature enclosure .
3-37

BNAU8758576
H DMSp01659501
NEC$ASIC ' S atsos00H
Figure 3 .32 Typical Vacuum Pumping System •
Pumps
Mechanical Pimps - are included in most vacuum systems to rough -evacuate the system
-
in the range from atmospberic to 10 2 tore . These pumps are of two general types,
the rotary vane and the rotary piston .
The most common cause of poor performance of a mechanical pump is contamination of

the o .l with a volatile substance such as water . A moderate contamination can be
removed by pumping air for several hours .
Most pumps have Check valves which prevent flow of oil into the vacuum system when
the pump is stepped . However, these sometimes leak, so it is safest to close the
valve between the mechanical pump mad the rest of the system and have a valve to let
air into the mechanical pump when it is stopped . To avoid damage to large pimps
with oil separation reservoirs it is advisable to turn the pump over by hand before
turning on the motor so that any ercess oil in the vorking volume of the pump is
gently discharged jots the reservoir .
Diffusion Amps - are most frequently used in pressures below 10-3 torr . Since this
type of pump cannot discharge to atmosphere , mechanical pimps are required to reduce
the pressure to the operating range of the diffusion pimp . The mechanical pimp re-
mov s bout 99 .P9 percent of the gas while reducing the pressure to 10-1 torr or bees.
The eremaining pressure from 10-3 torr or lower is removed by the diffusion pump dis-
charging into the mechanical pump.
•
3-38

BNA0875857 7
Cllifomia, No. CV 97-1554
H DMSp01659502
•
The lowest pressure attainable by the diffusion pump is determined in part by the
vapor pressure of the oil at the temperature of a ail ble cooling water . Oil dif-
fusion pumps should never be opened to the atmosphere when the oil is hot, as this
might cause decomposition of the oil .
Valves
Vacuum valves differ from more conventional valves in the following characteristics :
1 . Freedom from Leakage . Conventional packing on stems has been proven

entirely unreliable from a leakage standpoist . Vacuum valves use either
a bellows , an 0-ring or a diaphragm as a stem seal .
2 . Minimum Flow Resistance . The criteria for conventional valves (absence of

excessive pressure drop through the valve is insured if full area equal to
port area is maintained through entry section of the valve) is only a mini-
mum criterion for vacuum valves . Obstructions in the line of flow are not
permitted and the valve port should be completely uncovered . The latter
requires a stem lift approximating the diameter of the port .
3 . Absence of Outgassing . In vacuum systems outgassing of volatile materials

from sealing and lubricating greases and organic sealing materials cannot
be tolerated . Greases are used sparingly, or not at all, in vacuum valves
and where used , are special vacuum greases of low vapor pressure . Rubber-
like materials although gassy, are so efficient as sealers that they are
used is the majority of vacuum valves .
Gaskets and Seal s

•
One of the most widely used vacuum seals is the 0-ring made of neoprene , butyl rubber
or teflon . Gaskets made of soft metals such as lead , copper or aluminum may be used
over a wider temperature range than 0-rings due to their lower expansion and contrac-
tion . Typical seals are shown in Figure 3 .34 .
SYSTEM Ik1AK REPAI R
Leaks in joints that are kept at room temperature are sometimes sealed by painting
with a varnish such so Glyptal .
Leaks in gaskets usually require renewing or regressing gasket . Where soft metal
gaskets are used , a leak can sometimes be cured by annealing the gasket .
LEAK. DETECTION TESTS
The most sensitive, reliable , and convenient instrument used for leak detector tests
is the helium mass-spectrometer leak detector . A typical setup for leak detection is
shown in figure 3 .33 . After the equipment being leak -tested has been evacuated,
helium is sprayed over the outside of the equipment . If a leak is present, helium
will enter the equipment and be transferred to the mass spectrometer by its vacuum
pump . The cold trap shown is provided to protect the mass- spectrometer from volatile
substances that may be evolved by the test object . The mass-spectrometer indicates
any helium ions preseot inside the equipment . Leaks as small as 10-10 cubic centi-
meters per second can be located by u of this procedure . When spraying the helium
over the outside of the equipment it is important to start at the top of the equip-
ment because helium , being light , will rise, as that a leak may apparently be dis-
covered at the bottom of the equipment when the helium is actually entering throug h
a leak higher up .
•
3-39

BNAU8758578
H DMSp01659503
MFf RANIC'S HANDBOOK
•
EQUIPMENT REINS
TESTED-,
VALVE S
VALVE
COLD
TRAP S
LEAN DETECTOR
AUXILIARY PUMPING SYSTE M
Figure 3 . 33 Leak Detector Test Setu p
Another, more sensitive , method of using the helium mass - spectrometer is to com-
pletely inclose the equipsest being tested in a hood or inclosure and fill this area
with an atmosphere of pure helium . This method will not show the specific location
of the leak but will localize it to a small area . A joint or suspected leak area
may be tested by wrapping the joint or covering the area with a blanket of rubber or
other airtight flexible material . Insert small tube under the blanket . Seal the •
edges of the blanket to the system with tape and induce helium .
The third method of using the helium mass-spectrometer is to fill the area being
tested with helium at a pressure greater than atmospheric and use a aaiffer probe
that is connected to the leak detector . The sniffer is a fine valve at the end of a
probing tube that admits gas very slowly so the leek detector can be kept in its
operating range of 10 -1 Corr . This method is not as sensitive as the two previous
methods because a large amount of air is always taken into the probe along with the
small amount of helium escaping from the leak .
•
3-4 0
CONEIDENTLIL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA08758579
H DMSp01659504
PIPE, TUBE AMID FITTIM S
Vacuum Flanged Fitting With Gaske t Threaded Vacuum Line Fittin g
WELD JOINT WELD JOIN T
.f'w✓ ~,n
O-RING
VACUUM LINE
Vacuum Flocced Fitting With 0-ring Vacuum Flange Fitting for

Electrical Lead s
Figure 3 . 34 Typical Vacuum Seals and Gaskets
3-4 1
CONFfDEPTTAI LEVEL T- 17NDER PROTECTWE ORDER ,

BNA08758580
C;llifornia, no. CC 97-1554
H DMSp01659505
SECTION 4
VALVES AND REGULATORS
CONTEST S
Page
Introduction 4-1
Equipment Laboratory Procedures 4-1
Valve Rules 4-1
Valve Nomenclature 4- 1
Valve Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Gate Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Globe Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 3
Annie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Seat Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Needle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Solenoid Valves, 3-Way . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Marotta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Barksdale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Solenoid Valves, 4-Way . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
•
Barksdale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Empaasible Tube Valves . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Ball Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Burst Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 1
Pressure Regulators and Pressure Regulation Systems . . . . . . . . . . . . . 4-25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Large Volume Pressure Regulator (Grove Dome) . . . . . . . . . . . . .. . . 4-25
a.°1 l Volume Pressure Regulator Grove Bandleader ) . . . . . . . . . . . . 4-25
Pressure Regulator (Grove Mity Mite ) . . . . . . . . . . . . . . . . . . . 4-28
Pressure Regulation System . . . . . . . . . . . . . . . . . . . . . . . 4-28
Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

BNAU8758581
H DMSp01659506
•
INTRODUCTIO N
EQUIPMENT LABORATORY PROCDURE S
All valves procured for use at the Field Laboratories pass through the Equipment Lab-
oratory (E.L .) for inspection , lubrication , and identification . At the same time,
they are hydrostatically or pneumatically roof ffijxd to 1-1/2 times their maximum
working pressure a ag is then attached to a va ve o esig a
sp v ve should not be used for service other than that specified .
All valves at the Field Laboratories are rated at 100 F and the maximum working pres-
sure at this temperature is stamped on the valve body . This maximum working pressure
incorporates a safety factor of 4 . The pressure marked on the valve should never be
exceeded .
A Qualified Equipment List compiled by 2/096-211, Equipment Engineering , gives perti-

nent information on valves and other components suggested for use at the field lab-
oratories .
VALVE RULES
1 . All valve repairs and adjustments must be performed by Qualified personnel .
2 . Relief valves are tagged with check due dates and must be checked annually .
3 . High-pressure hand valves are precision instrnmants and care should he ex-
ercised to avoid damage by over-tightemimg .
• 4 . Valves should be used only under the pressure nod service conditions stamped
on the valve body .
5 . Packing gland nuts and flange nuts sbouiu sot be tightened while the eystem
is pressurized .
6 . Safety wire should never be cut and the lead seal should never be removed
from valves by other than qualified personnel .
VALVE NOMENCLATt1EE .
The following illustration (Figure 4 . 1) shows the parts of a typical valve . Terms in
common see inelade :
Trim---The plug and seat combination . Metal to metal , 0-riag to metal, and soft
seat ore common applications .
Plmg ---The movable portion which contacts the seat to form a seal . Different
shapes are used to produce different opening characteristics .
Seat---The orifice through which the fluid flows . It is either all metal or is
metal with a plastic insert which contacts the plug (soft seat) .
•
4-1

BNA0875858 2
H DMSp01659507
ANNIN)
FIG 4 .1 NORMALLY CLOSED-PNEUMATIC CYLINDER ,OPERATED _VALVE (
(WITH COOLING FIN FOR CRYOGENIC OR HOT GAS SERVICES
4-2

BNAU8758583
H DMSp01659508
VALVES AND REOVIATORS
•
Stem --- The connector between the actoetor and the plug .
Body---The main part of a valve . The part to which lines are attached by means
of flanges or threaded bosses . (Both AN straight thread and NIT threads
are in use . )
N.C,---Normally closed (valve) . A valve that is closed when de - energized .

N .O .---Normally open (valve) . A valve that is open when de-energized ,
VALVE TYPES
The many pneumatic and hydraulic systems used at the Field Laboratories require many
types of valves . Each valve type has some characteristic which makes it suitable for
a particular s e The different valve types very in operation and the care re-
quired for reliable service .
The following descriptions and illustrations represent the most used valves, their
particular characteristics , and any special precautions necessa ry for reliable opera-
tion .
GATE VALVES
The major advantage of a gate valve is that it allows unrestricted fluid flow . The
valve gate seals by a wedging action . (See Figure 4 .2 . )
Gate Valve (Grove Seal-O-Rings )
This gate valve uses Kel-F 0-rings and a parallel sided gate rather than the usual
Rel-F to metal seat and wedge gate to form the seal . The use of neoprene 0-rings
•
makes it unusable in liquified gas service because of the low temperatures involved .
This valve is in the 6000 psi pressure range . Sealing is independent of shutoff
forces . (See Figure 4 .3 . )
GLOBE VALVES
Ami n
The Annin Company manufactures a globe valve which is furnished in a variety of

sizes, trim , connections , and operating pressures . Step packing is normally of chev-
ron teflon . Some valves use metal to metal trim , but a metal plug and a Kel-F soft
seat are more common. Operation of this valve is effected by a nonrising manual
handle or by a pneumatic cylinder , either of which can be attached to the basic valve .
There are two types of pneumatic cylinders , normally closed (N.C .) and normally
opened (N.O .) . The Amin pneumatic cylinders ere limited is 150 psi maadm® pres-
sure (normal operation is in the 120 to 135 psi range to allow relief valves to be
M. at 150 psi), aced Domotors to 100 psi . Annie valves can have high pressure cylie-
ders, such as Miller cylinders . (See Figures 4 .4 and 4 .5)
4-3
CDNFID ENTLVL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA08758584
Cllifornia, No. CV 97-1554
H DMSp01659509
MECHANIC'S HANDBOOK
LOCKING SLUG
BUSHING NUT, YOKE
KEY, HANDWHEEL
GREASE FITTING
FIG . 42 GATE VALVE (ALOYCO )

•
4- 4

BNA0875858 5
H DMSp01659510
VALVES AND REBITLATORS
MANUAL OPERATING MECHANISM

FIG . 4.3 GATE VALVE ( GROVE SEAL 0-RING )
•
4- 5

BNAU8758586
H DMSp01659511
MECHANIC'S BAPIDBOOK
PNEUMATIC CYLINDERS
-~ OU T
IN
SPLIT VALVE BOD Y
.FIG . 4.4 . GLOBE VALVE (ANN IN )

•
4-6

BNAU8758587
H DMSp01659512
FIG . 4 .5 . RELATIONSHIP OF ANNIN VALVE TO 4-WAY

SOLENOID VALVE ( SOLENOID ENERGIZED )
•

BNA0875858 8
H DMSpO1659513
MECHANIC'S HANDBOOK
Seat Seal Valve ( Grove )

•
The Grove T series is typical of thin type o£ globe valve . Sealing of the seat seal
valve is effected by an 0-ring rather than by the standard trim of plug and seat .
Farther tightening after the 0-ring has entered the neat will a etal plug to
contact the seat. Tightening beyond this point may result in seat m damage , and damag e
is certain if strong hand pressure is exerted on the valve handle . Damage to the seat
causes scuffing of the 0-ring during opening and closing , with subsequent leakage past
the 0-ring seal . The Grove T series comes in 1/b , 3/8, and 1 /2 inch sizes for work-
ing pressures up to 6000 psi .
In addition to the 0-ring seat seal , an 0-ring seal is used around the stem, elimi-
nating stuffing box difficulties . (See Figure 4 .6 . )
Needle Valve
This valve is a modification of a globe valve and is designed for high-pressure use
(10,000 psi) . The stem is tapered to form a plug and the seat is built with a very
small plug contact area . This small contact area in the trim results in high seat-
ing pressure from a relatively small force on the stem . Any undue force applied to
the valve handle will damage the trim . Two-finger shutoff is sufficient for this
type of valve . ( See Figure 4 .7 . )
SOLENOID VALVES, 3-WAY
Solenoid valves are actuated by electrical energy . A direct- acting solenoid valve Is
one in which the opening and closing are controlled osly by the solenoid . A pilot-
operated solenoid valve i one in which the solenoid eontrols the flow of a small
pcrtion of the fluid which is in torn used to operate the main valve . The pilot-
operated vnlve , however , requires a certain minimum fluid pressure before it will
open or close (usually 30 psi) . •
Marott a
This solenoid valve is a direct-acting valve and is opened or closed ompletely by

the action of the electric solenoid (28 v . 0 .1 .) . There are two inlet /vent parts
and one outlet or cylinder port . Whether this valve is N.C . or N . O . depends on how
the inlet pressure is plumbed . Energizing the solenoid closes one fluid path and
opens the other . The Marotta MV - 74p and MV-543 models are examples of this type of
valve . ( See Figure k.8 . )
Barksdale
The Barksdale solenoid valve is pilot- operated . It uses a solenoid to control fluid
flow to a piston which opens or closee the valve . This valve is limited to 250 psi
and is used to control flow to the basin pneumatic cylinders . The Barksdale is
furnished in two types . N .O, and N .C . (See Figure 4 .9 . )
a-e •
CDNFIDENTLVL LEVEL I- UNDER PROTECTIVE ORDER ,

BNA0875858 9
Cllifornia, No. CV 97-1554
H DMSp01659514
FIG . 4,6. SEAT SEAL VALVE ( GROVE )
•
4- 9
CDNFH)F,nTTAT, T,F,V'F, T, T- i7N1)F, R PROTF,CTWE ORI)FR,

BNA0875859 0
H DMSp01659515
MECNtNIC 'S HANDBOOK
FIG 4.7 NEEDLE VALVE
•
4-10

BNA0875859 1
California, Po. Cl 97-1554
H DMSp01659516
VALVES AND REGUTATORS
FIG . 4.8 . SOLENOID VALVE, 3-WAY

(MAROTTA )
•
4-I 1
CDNFfDENTTAT, LEVEL T- i7NDER PROTECTTVF ORDER ,

BNA0875859 2
California, I o. CV 97-1554
H DMSp01659517
N IIANIC S ILANDBOOI{
PILOT
PRESSURE
SEAL
PILOT
EXHAUST
SEAL
PISTON
PILOT CHAMBER
SUPPLY
PASSAGE MAIN
VALVE
MEMBER
PRESSURE
FIG . 4 .9 SOLENOID VALVE, PILOT-OPERATED ( 3-WAY BARKSDALE)
4-12

BNAU8758593
H DMSpO1659518
VALVES AND UEGinATOR S
SOLENOID VALVES, 4-WAY
The 4-way type valve can be used in place of two 3-way valves for control of a pneu-
matic air cylinder-operated valve . The ports are arranged so that one set is venting
while the other is pressurizing . (See Figure 4 .10 . )
Barksdale 4-Way
This pilot-operated 4-way solenoid valve requires a minimum operating pressure of

50 psi . It is used to control a neum tic ijA opa*a
_ tod
s-~ vt
a.l~e_inplace-,f .. 5wp3-way
control valves . See Figure 4 .5 and 4 .11 .) Note : Do Not restrict the vent port .
EXPANSIBLE TUBE VALVE S
The Grove Flexflo is an example of the expansible tube type of valve . It is designed
to be operated by pressure from the upstream supply pressure , a solenoid valve being
used to control the upstream fluid pressure which actuates the Flexflo valve . The
pressure i equal on both sides of the expansible tube , but greater area is exposed
to fluid pressure on the outside surface . The valve will stay closed while control
pressure is on . Venting the control pressure allows the tube to expand and the valve
to open . (See Figure 4 .12 . )
CFI£TIS VALVE S
Check valves operate on differential pressure and allow flow in one direction only .
All restrict flow to some extent . The most common check valves used are the Split-
• Flapper type and the Poppet type .
The Split-Flapper type consists of two semi - circular discs hinged to a pin . Flow
through the valve in the forward direction moves the discs , parallel to the flow
stream and into the center of the valve . This type in more common in the larger
sizes ( 3° and up ) and has the advantage of minimum pressure drop per given size .
(See Figure 4 .13 .) -
The Poppet type consists of a sliding poppet which is closely guided in the valve
body and the head of which seals against an 0-ring or metal seat . Flow through the
valve in the forward direction forces the poppet off the seat and permits flow around
the poppet and through the valve . Because of close tolerances within the valve, con-
tamination or dirt can cause sticking end leakage . (See Figure 4 .14 . )
RELIEF VALVE S
The typical direct operating relief valve utilizes a preset spring load to prevent
valve opening . These valves have a set pressure tolerance of 2 psi for set pressures
through 70 psi, and 3 percent for set pressures over 70 psi . They must reseat before
the pressure falls below 90 percent of set pressure . The trim consista of 0-ring,
plastic or metal seat and metal nozzles . (See Figure 4 .15• )
The pilot operated relief valve (AGCO ) differs from the direct acting relief valve
primarily due to the application of a separate direct operating relief valve ( pilot)
for control of pressure forces acting on the main valve piston . ( See Figure 4 .16, )
4-1 3

BNAU8758594
H DMSp01659519
2ffiCHANIC ' S HANDBOOK
VEN T
CYLINDER 2 .
PRESSURE
CYLINDER I .
PRESS. PRESS .
MM".MRS: _"
111-'_1 oi/ :11;11;11,1 ;
WE"
CYL . 1. VENT CYL . 2 . CYL . I . VENT CYL . 2 .
DE-ENERGIZED POSITION ENERGIZED POSITIO N
FIG . 4 .10 . SOLENOID VALVE, 4-WAY
4-14
CONFT)F,1TTAT, LEVET, T- UNDER PROTF.CTTVF. ORDER ,

BNA0875859 5
H DMSp01659520
• •
EXH. 4EXH .
L.2 )CYL 2
OIN 'IN Cn.i
NORMAL POSITION DE-ENERGIZE D ENERGIZED POSITIO N
FIG. 4.11 SOLENOID VALVE, 4-WAY (BARKSDALE)

MECHtNIC'S HANDBOOK
HYCAR EXPANSIBLE TUBE

CORE
OUTLET SLOTS
JACKET
CONNECTION •
VALVE PARTS
OPERATIO N
FIG 4.12 EXPANSIBLE TUBE VALVE

(GROVE FLEXFLO)
•
4-16
CONFTDENTTAT, LEVEL I- ITNDF, R PROTF,CTTVE ORDER,

BNA0875859 7
H DMSp01659522
VALVES !SID RDGULATOR S
4-1 7
CDNFIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER,

BNA0875859 8
H DMSp01659523
BACK-UP RING
OUTLET POR T
FIG . 4.14. CHECK VALVE (POPPET TYPE )
• 0 •
VALVES ANT REGULATORS
FIG_ 4 .15 RELIEF VALVE (DIRECT ACTING )
4-1 9

BNA08758600
H DMSp01659525
PU
O
SCRFW, DRIVE
NAME PLATE
--- CONNECTOR
TUBE , SUPPLY
NIPPLE
CAP, BOLT
CAI 600 N 0
j- SCREW - LIFT STOP RET
N0621FLAT MEA D
SEAL,LINE R
SEAL, BONNET
STOP, LIFT
NOZZLE, NIGH PRESS
SPRING CAGE
SEAL, NOZZLE PRESSURE RING
LOCKWIR E
LOCK NUT SEAL, PISTON
NEEDLE ADJUSTING
SEAL
WELOMEN T. BODY
FIG . 4.16 PILOT OPERATED RELIEF VALVE (AGCO)
0
• BALL VALVES
Ball valves are used as shut-off valves in lines where a low pressure drop across the
valve is desired . The ball valve, like the gate valve, allows unrestricted fluid flow
with the additional advantage of eliminating the turbulence usually caused by the
large body cavity of the gate valve . However, a e ball valves tend to leak at low
inlet pressures due to the fact that the ball " floats" between two seat seals . Ther e
of stopping seat leakage by tightening down the handle as with a globe or
gate ovalve . ( See Figures 4 .171 and 4 .18 . )
BURST DIAPHRAGMS
The burst diaphragm or safety head is a device used to prevent excessive pressures or
to allow flow at predetermined pressure . The diaphragms are fragile and care most
Is used en installation to prevent creases , bends, or cuts ; and clamping surfaces
must be kept free of dirt or grit . Diaphragms are installed so that pressure is
against the concave side . Since they are rated at a particular temperature (usually
72° F), the burst pressure must be redetermined for use at other temperatures . Burst
diaphragms should be operated at 66 percent of the design burst pressure for normal
burst , diaphragm life . Vent lines must be positioned so that fluids are carried away
from personnel . ( See Figure 4 .19 . )
4-2 1

BNAU8758602
H DMSp01659527
MECHANIC'S HANDBOOK
•
4-22

BNA08758603
H DMSp01659528
WASHER-SPRING LOCK
PLATE-BASE
O-RIN G
• INSERT-SCREW THD
FLANGE-BODY
SEARING- NEEDLE
RACE, INNER
WASHER, BEARING
WASNER,THRUST
FIG . 4.18 BALL VALVE WITH PNEUMATIC ACTUATOR (18" )

•
4-23
CDNFIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA08758604
California, No. Cl 97-1554
H DMSp01659529
FLOW
FIG . 4.19 BURST DIAPHRAGM
•
4-2 4

BNA08758605
HDMSpO1659530
VALVES AND PARUL4TORS
PRESSURE REGULATORS
AND
PRESSURE RRIIJI .ATION SYSTEMS
GENEML
An orifice regulates flow under dynamic conditions, but it does not function under
static conditions . Automatic valving incorporating a diaphragm and plug to regulate
pressure under dynamic or static conditions is a satisfactory method used in most
mechanical regulators .
LARGE VOLUME PRESSURE REGULATOR (GROVE DOME )
This regulator is of the diaphragm type and is made in 3 basic sizes (series 200, 300,
400) with additional valve trim variations in each series . The dome, which controls
the pressure on the diaphragm, can be either internally loaded or externally loaded .
External loading is usually with a Grove small volume hand regulator . This allows
easy settiug of the downstream regulated pressure . In operation the trapped pressure
within the dome moves the large flexible diaphragm, forcing the reverse acting plug
off its seat . The supply pressure entering the regulator is then permitted to flow
through the open valve and into the reduced pressure line . An internal sensing
passage transmits this pressure to the underside of the diaphragm . When the delivered
pressure in the downstream line approximates the loading pressure in the dome and the
unbalanced forces are equalized , the plug is closed . With the slightest drop in
downstream pressure , the pressure trapped in the dome instantly forces the plug open
allowing sufficient flow to return the delivered pressure to the set point . (See
• Figure 4 .20 . )
SMALL VOLUME PRESSURE REGULATOR (GROVE HANDLOADER )
The Grove small volume high pressure regulators or "handloaders " as they are famil-
iarly known, . are most commonly used to maintain a constant pressure within the domes
of the grove dome regulators . The pressures coming from these regulators are subject
to temperature variations . The handloader is stocked in several models which deter-
mine the inlet and outlet pressure ranges . Inlet pressures are either 3000 psi or
6000 psi, while the regulated pressure is available in a wide variety of ranges from
0 to 6000 psi .
In operation , as compression in the spring is increased by manually turning the hand-

wheel, the inlet valve is forced from its seat, thereby admitting pressure to the
diaphragm chamber and outlet line . When this pressure on the diaphragm produces a
force equal to the adjusted spring compression, the diaphragm r , thus closing the
inlet valve . When the spring force is reduced by turning the handwheel counter clock-
wise, pressure in the diaphragm chamber is greater than the spring force , the dia-
phragm assembly and relief valve seat rise, opening the relief valve and thus reducing
the outlet pressure .
The sensitivity of this handloader is a function of the bleed adjustment, which cor-
rects minor deviations beyond the scope of the main diaphragm spri This bleed is
adjustable by a small screw under the acorn nut . (see Figure 4 .21.
)
NOTE : Raudloaders should aot be used in gaseous hydrogen service . The hydrogen
bleed presents a fire hazard .
4-2 5

BNAU87586U6
Califnrnia, No. CV 97-1554
H DMSp01659531
0
FIG . 4 .20 LARGE VOLUME PRESSURE REGULATOR (GROVE DOME)
0
VALVES AND EMULATORS
FIG . 4.21 . SMALL VOLUME PRESSURE .REDUCING

AND RELIEF REGULATOR
(GROVE HANDLOADER )
4-2 7

BNAU8758608
H DMSp01659533
MECPANIC' S RAIID000&
PRESSURE REGL°I4TOR (GROVE MITT MITE )

•
Model 94-RR is a reducing and relief valve available in 1/4-, 1/2-, and 1-inch end
connections for inlet pressures to 6000 psi and outlet pressures to 5000 psi . The
operation of this regulator is similar to the dome regulator with the addition of a
relief pert which will vent off downstream pressure i oscsss of the static loading .
This regulator measures only 2-3,4 by 3-1/4 inches . The Mity Mite is also available
without the relief feature for inlet pressures to 10, 000 psi sod outlet pressures to
6000 psi . ( See Figure 4 . 2 2 . )
PRESSURE RDGULATION SYSTEM
The small volume pressure reducing and relief regulator regulates the static pressure
to the dome of the large volume regulator . The pressure in the dome actuates the
large volume regulator valve which maintains a constant pressure downstream of the
regulator . Increasing dome pressure opens the large volume regulator valve and in-
creases downstream pressure . Decreasing dome pressure closes the large volume regu-
lator valve but will not decrease the downstream regulated pressure . To decrease
downstream regulated pressure , the manual vent valve must be opened .
It i important to note that only the downstream pressure gauge indicates the regu-
lated pressure . The dome loading pressure gauge does mot read regulated pressure .
(See Figure 4 .23 . )
The three-way solenoid valve shown between the small volume regulator and the large
volume regulator (Figure 4 .23), may or may not be plumbed into a system . The three-
way solenoid is used for remote control of a regulation system .
CONTROL VALVE INSTALLATIO N

•
Figures 4 . 24, 4 .25 and 4 .26 show typical usage of regulated pressures in the control
plumsing of an Annie valve installation , and its operation, with the use of two three-
way solenoid valves and one four -way solenoid valve .
•
4-2 8

BNA08758609
H DMSp01659534
• 10 •
PRESSURE
RELIE F
(TOP VIEW)
STA71C OPER . PRESS .
PR
URE
(SIDE VIEW )
FIG . 4 .22 PRESSURE REGULATOR(GROVE MITY MITE)

D
0
REGULATED PRESSURE GAG E
SMALL VOLUME REGULATO R

PRESSURE GAGE
REDUCING
AND RELIEF LARGE VOLUME
REGULATOR PRESSUR E
REGULATO R
DOME
FIG 4 .23. PRESSURE REGULATION SYSTEM (PNEUMATIC PANEL)
•
T
+28 VDC
150 PSI (MAX)
GNa SUPPLY
PRESSURE -WA
VY
VALL . CONTROL
SWITCH
CLOSING
PORT
NORMALLY CLOSED VALVE ( CLOSED POSITION )
The opening and closing control valves for the Annin valve installation shown below
are plumbed as follows :
U
~~ The Normally Open (N .O .) - 3-way control valve (Marotta) is plumbed to the Armin
valve closing control port.
..•!' The Normally Closed (N .C .) 3-way control valve (Marotta) is plumbed to the Annia
valve opening control port .
The two 3-way control valves are operated with one switch . By closing the switch the
Armin valve is opened, by opening the switch the Annin valve is closed .
When the Annin valve is in the closed position ( as shown), the opening control pres-
sure below the piston is vented to atmosphere through the normally closed control
valve's normally open port .
When the Annin valve is open , the closing control pressure above the piston will be
vented to-atmosphere through the normally open control valve's normally closed port .
This Annin valve is plumbed Fail Safe Closed . In case of an electrical power failure
the Annin valve will return to the closed position . In case of GN2 control pressure
failure, the spring installed above the piston in the Annin valve will return the
Armin valve to the closed position .
Figure 4 . 24 Relationship of Annin and Solenoid Control Valve s
4-3 1

BNAU875861 2
H DMSp01659537
MECHANIC'S HANDBOOK
150P$1 (MAX)
GNZ +28VDC
SUPPLY
PRESSURE 3-WAY MAROTTA
VALVE CONTROL
SW ITCH CLOSING PORT
NORMALLY OPEN VALVE ( OPEN POSITION )
•
The opening and closing control valves for the Annie valve installation shown below
are plumbed as follows :
The Normally Open (N .D .) 3-way control valve (Marotta ) is plumbed to the Annin valve
opening control port .
The Normally Closed (N .C .) 3-way control valve (Marotta ) is plumbed to the Annie
valve closing control port .
I,
The two 5-way control valves are operated with one switch . By closing the switch the
Antic valve is closed , by opening the switch the Annie valve is opened .
When the Annie valve is in the open position (as shown ), the closing control pressure
above the piston is vented to atmosphere through the normally closed control valves
normally open port ,
When the Annin valve is closed , the opening control pressure below the piston will be
vented to atmosphere through the normally open control valve ' s normally closed port .
This Annie valve is plumbed Fail Safe Open . In case of an electrical power failure
the Annie valve Will return to the open position . To casof GN2 control pressur e
o failure, the spring installed below the piston in the Annie valve will return th e
Annie valve to the open position .
Figure 4 .25 Relationship of Annie and Solenoid Control Valves
•
4-32

BNA0875861 3
H DMSp01659538
VALVES MID REGULATORS
•
150 PSI (MAX) GNz 4-WAY
1 VALVE
SWITC H
CLOSING
FXH,j PORT
9r
IN SPRING
OPENING
PORT PISTON
CYLI 'I YCYL' 1r
# c2
VALVE
POSITION
INDICATOR
4-WAY(CRESCENT)
PLAT E
SOLENOID VALVE
(DE-ENERGIZED POSITION )
}
FLOW
The Crescent Pilot-operated 4-Way Solenoid Valve requires a minimum operating pres-
•
sure of 30 PSI . It is used to control a pneamatically- operated valve in place of two
3-Way control valves .
The opening and closing control pressures for operation of the Annin Valve are plumbed
as follows :
A supply pressure of 150 PSI (Max.) is plumbed to the IN port on the 4-Way valve .
The 4-Way valve in a de-energized state with pressure up will have a flow path from
the IN port to the CYL. port .
The 4-Way valve in an energized state with pressure up will have a flow path from
the IN port to the CYL, 1 port .
The 4-Way valve CYL, #2 is plumbed to the closing control port on the Amin Valve,
so that with pressure up and the 4-Way valve de-energized a constant supply of pres-
sure is holding the Annin valve closed .
The 4-Way valve CYL . 1 is plumbed to the opening control port on the Annin Valve,
so that with pressure up and the 4-Way valve de-energized the opening control pres-
sure is vented to atmosphere through the Exhaust port on the 4-Way valve .
When the 4-Way valve is energized the pressure in the CYL . #2 is vented to atmosphere
through the Exhaust port and CYL . 1 i opened to pressure . When the 4-Way valve is
energized, the Annin Valve will open if plumbed as shown .
This Armin Valve is plumbed Fail Safe Closed . In case of an electrical power failure
the Annin Valve will return to the closed position from an open position . In case of
GN1 control pressure failure, the spring installed above the piston in the Annie
valve will return the valve to the closed position .
Figure 4 . 26 Annin Valve (Closed Position)
4-3 3

BNA0875861 4
H DMSp01659539
SECTION 5
FASTII HIS
CONTETTS
Page
General . 5-1
Instellatios of Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fastener Head Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Piss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Applying Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Torquing Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Torquing Flanged Fittings . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Torque Wrenches and Their Use . . . . . . . . . . . . . . . . . . . . . . 5-20
How Adaptors Affect Torque . . . . . . . . . . . . . . . . . . . . . . . 5-2 2

BNA0875861 5
H DMSp01659540
FASTIIJII.S
•
FASTENOZS
G1N18AL
AN bolts are generally used to fit through a hole rather than to thread into one .
Bolts are classified by size, configuration, and tensile strength under an AN speci-
fication heading . Alt is the Air Force-Navy symbol for a specification standard .
Make certain that the bolts to be used and installed are the ones called sot on the
drawing ( or other doocment ) . Do not substitute bolts unless proper authorization has
been secured .
Screws are generally used in applications where they are screwed into a threaded hole
rather than fitted through a clearance bole . Screws are also categorized and identi-
fied by AN numbers . Care must be taken to use the recommended configuration, size
and, strength for a particular job .
Nuts are generally used to secure or immobilize some component or assembly . The AN
prefix, as well as other means of identification , are uoed to classify nuts at
Recketdyne .
Washers are generally used as a seat for bolt heads and nuts . The function of a
washer may be to keep a bolt or nut from untbreading , to act as a spacer , or serve
as a device which will allow a bolt to be stressed to its proper torque value with
a minimum of frictioual resistance .
Pins are used in fastening parts together . Pins are usually designed for close fit
end may be designed to be forced into contact with mating parts .
Safety wiring is a method of securing nuts, bolts, screws , and other fasteners to
• keep them from vibrating or shaking loose . Methods of securing fasteners are accom-
plished in a number of ways, such as safety wiring and tack welding .
INSTALLATION OF FASTENamS
All threaded parts shall be installed as shown on the drawing . Lubrication shall not
be used ( except as shown on the drawing ) where both threaded parts are bare corrosion-
resistant steel . Tightening shall be accomplished by rotating the nut if possible .
Torquisg of all fasteners designated on drawing calleut as fasteners having tensile

strengths of 160,000 psi and greater shall be performed by applying the apeeified
torque to the fasteners , then back off at least one full turn and reapply the speci-
fied torque .
Dceessive tightening of nut will overstress the fastener, causing distortion or strip
ping of the threads , while insufficient tightening results in loose joints . Fas-
teners which have been bottomed or the threads otherwise damaged shall be replaced .
Structural bolts or screws one dash number above that called out on the Facility
Drawing may be used provided the thickness of the thinner flange at the joint as
called out on the drawing at the bolt bole location is 0 .125 inch or greater.
• 5-1
CONPTDTNTTAT . T,TVPT, T- ITNDTR PI1OTPCTWE O It l)PR ,

BNA0875861 6
H DMSp01659541
MECHANIC'S HANDBOON
For structural joints additional washers of the s callout may be added up to a •

total added thickness of 10 percent of the thickness of the thinner flange as called
out on the drawing at the bolt hole location . Structural fastener applications as
indicated on the drawing are defined as follows :
1 . Fasteners used to join pressurized component s
2 . Fasteners used to join components carrying carrying loads , n eeasary to

achieve the design functions of the assembly
When the drawing calls out an application as being nonstructural , bolts or screws
three dash numbers above or below that called out on the drawing may be used, pro-
vided no interference occurs as a result .
Bolts used with self-locking nuts and inserts must be without cotter pin holes in
threaded shank .
Bolts and screws shall run free enough to engage the threads of threaded parts by
hand without using a wrench .
Caution : There have been mishaps caused by substituting bolts of a different (and
weaker ) material, even though the correct size bolt was used . Do not interchange
bolts made of different materials .
FASTENER HEAD STYLES
Some typical fastener head styles are shown in Figure 5 .1 . For more detail see the
Standards Manual .
Bolt and Cap Screw Head s

•
Hexagon Head (Trimmed) . . . . . . . . . . . . . . . . . . . . . .
Square Head (Trimmed) . . . . . . . . . . . . . . . . . . . . . .
Socket Head . . . . - - - - - - - - - - - - - - - - -
Round Head Square Neck (Carriage ) . . . . . . . . . . . . . . . .
Pan Head Oval Neck . . . . . . . . . . . . . . . . . . . . . . . .

O
Countersunk Head . . . . . . . . . . . . . . . . . . . . . . . . .
8
Elevator Bolt Head . . . . . . . . . . . . . . . . . . . . . . . .
5-2
Figure 5 .1 Fastener Head Styles (Sheet 1 of 2 )
•

BNA0875861 7
H DMSp01659542
FASTENS .S
• Screw Beads (Machine , Wood , Tapping , Stove Bolts )
Flat head
Round Head . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Oval Head . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e
Fillister Head . . . . . . . . . . . . . . . . . . . . . . . . . .
Binding Head . . . . . . . . . . . . . . . . . . . . . . . . . . .
Truss Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . e
Pan Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e
• Jackson Head . . . . . . . . . . . . . . . . . . . . . . . . . . . e
Welding Screw Head . . . . . . . . . . . . . . . . . . . . . . . .
Knurled Head
Set Screw Heads

. . . . . . . . . . . . . . . . . . . . . . . . . . .
0
Square Head Set Screw . . . . . . . . . . . . . . . . . . . . . .
Headless Slotted Set Screw . . . . . . . . . . . . . . . . . . . .

Il l l l~~~i.l
~II~~~II I Ih!_I
Socket Head Set Screw . . . . . . . . . . . . . . . . . .
. e
Figure 5 .1 Fastener Head Styles ( Sheet 2 o£ 2)
5- 3

BNAU875861 8
H DMSp01659543
MECHANIC'S 5552)800K
BOLTS
•
Bolt numbers consist of a basic number followed by a dash member . Sonic number s
indicate the type, diameter of shank, and thread size . Dash numbers indicate the
length . As bolt lengths are not consistent betwees AN designations , the specific AN
designation should be consulted for the dash number of the length required . Complete
tables of AN designations are available in the Standards Manual . Basic numbers and
dash numbers of both are interpreted as follows :
AN4-10 1 /4" diameter , 1-132 long, with cotter pin hole
0515-7A . . . . . . . . . 5/16" diameter , 3-1/32 " long, without cotter pin

hole (undrilled )
A5155-61 . . . . . . . . . 5/16" diameter , 27/32" long, drilled head, without

cotter pin hol e
SCRbWS
Serew numbers consist of the basic number followed by two dash numbers . The basic
number indicates the head shape . The first dash number indicates the diameter of the
screw. The second dash number indicates the length of the screw .
The absence of a letter before the first dash number indicates a carbon steel screw .
The letter "C" before the first dash number indicates a corrosion - resistant steel
screw. The letters " Dl' before the first dash number indicates an aluminum alloy
screw .
The letter 'R" between the first and second dash number indicates a recessed head .
The absence of a letter between the first and second dash number indicates a slotted •
head screw.
Screw head markings such as dashes or crosses indicate screw material . The symbols
used 0e5 7 among the different screw types . Cousult the Standards Manual for specific
infcrmation .
Example :
A N 5 0 7- 4 2 8 R 20
`Second dash number - length
Recessed head ( booms of letter indicates slotted

bead )
First dash comber - diameter
Basic screw type
•
5-4
CONEIDENTLAL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA0875861 9
H DMSp01659544
FASTENERS
• NUTS
Nut numbers consist of the basic number followed by a dash number . Basic numbers
indicate the type of nut ; dash numbers indicate the diameter in 1/16ths . Nuts are
steel unless otherwise coded (except 111311) .
The addition of the letter C before the dash number indicates corrosion -resistant
steel . The letter D before the dash number indicates aluminum alloy . The absence
of a letter before the dash number indicates carbon steel . The letter L after das h
umber indicates a nut with a left-hand thread . The letter R after dash number in-
dicates a nut with a right-hand thread . A complete list of nuts and their specifica-
tions can be found in the Standards Manual . This numbering pattern does not apply to
Bocketdyme Standard Nuts . .
Ercmple :
All 315 C 7 TR
L.Aight-hand thread
Dash number -- not size
Material -- corrosion-resistant steel

(absence of letter indicates carbon steel )
-Basic nut type
WASHERS
Washers are available in a variety of types, sizes, and materials . Washer numbers
consist of a basis number , which indicates the type of washer, followed by a dash
•
comber , which indicates the size of the washer .
Additional letters before the basic number or before or after the dash number refer
to variation of shape, material , or thickness . The symbols msed vary am ong the dif-
ferent masher types . Consult the Standards Manual for specific information .
Example :
AN935-iOL . . . . Steel lock washer for #10 bolt ( light)
.5109362102 . . . . Bronze washer, external teeth , for #10 bolt
2W17-416M . . . . Corrosion-resistant steel washer . 032 thick fo r

1/4" diameter fastene r
M520002C8 . . . Countersunk washer with 1/2" nominal I D
PINS
Pin types and sines are identified by part numbers . The part number consists of the
basic nomber followed by one or two dash numbers . The basic number indicates the
type of pin ; for flat head pins it also indicates the length . If there are two dash-
numbere , the first dash comber indicates the diameter and the second dash comber in-
dicates the length .
Example :
A10380-4-4 . . . . Steel cotter pin, 1/8" diam eter, 1" long

.510392-7 . . . . . Flat head steel pin, 1/8" diameter , 7/32" grip
5-5
CONFIDENTIAL LEVEL I -UNDER PROTECTIVE ORDER ,

BNA0875862 0
H DMSp01659545
MECHANIC ' S HAM)B00H
SAFETY WIRING
APPLYING FASTSIIERS
•
Where lockwire is specified and aluminum seals are shown on the drawing each lockwire
pigtail shall be sealed .
Lockwire and cotter pins shall be installed only one time ; destroy if removed for any
reason . Avoid sharp bends (kinks ) and picking in both lockwire and cotter pins .
Lockvire shall be as short as possible and attached in the most direct manner . The
double-twist method of safety wiring shalt be used as the common method of safety
wiring . The single -wire method of safety wiring may be used on small screws in a
closely spaced closed geometrical pattern (triangle , square, rectangle , circle, etc .) .
on parts in electrical systems and is places that are difficult to reach that would
make the single -wire method more advisable .
When safety wiring widely spaced multiple groups by the doable - twist method, three
units shall be the maximum number in a series . When safety wiring closely spaced
multiple groups, the number of units that can be safety wired by a 24-inch length of
wire shall be the maximum number in a series .
Parts shall be safety wired in such a manner that the safety wire shall be put in
tension when the part tends to loosen . A pigtail of 1/4 to 1/2 inch ( 3 to 6 twists)
shall be made at the end of the wiring and shall be bent back or under ( in a direction
to iacrease the tension ) to prevent it from becoming a snag . If an attach point to
the structure is required ( as when safetying a single bolt it shall be made only
where shows on the drawing .
Safety wire shall always pass around the fastener head except on MS type internal
wrenching tapered head bolts , is which case the wire shall pans over the head .
Figure 3 illustrates typical examples of these two variations . In safety wiring
Nullin grooved-head type screws the safety wire shall pass around the head and be
contained within the grooves provided . (See Figure 5 .2 . ) •
Threaded fasteners in propellant feed systems shall be lock wired ( i£ they are not
tack welded ) per new FLao06 _
THREE (3) TWISTS MINIMUM ;

SIX(6) TWISTS MAXIMUM
5-6
Figure 5 . 2 Lockwiring
i

BNA0875862 1
H DMSp01659546
p&srqans
I cori PINS
There are two methods of installing cotter pins . ( 1) Where one end of the cotter
pins goes over the top of the nut and (2) where ends go around the flats of the nut
(ace Figure 5 .3 ) . The first method is preferred and should be osed -whenever possible,
except for human safety precautions , interference with clothing or equipment, and
flat head pins . (See Figure 53 .)
FLAT HEAD PINS
Figure 5 .3 Pia Installation
• 5- 7

BNA0875862 2
H DMSp01659547
rf CRAHIC ' S h ANDBOOK
•
ALLOWABLE TILT UND TAE BEAD OF BOLTS AND SCREW S
Maximum a eepteble tilt under the bead of bolts end protruding head screws end the
maximum axxeptable gap under the head of flush head fasteners shall net exceed
0.105 inch . (See Figure 5 .4 )
BOLTS FLUSH HEAD SCREWS
A. 8.
Figure 5 .4 Allowable Tilt Under Head of Bolt s
•
LOCATION OF BOLT HOLES
Bolt heads shall be fully bearing on material . (See Figure 5 .5 . )
NOT ACCEPTABLE ACCEPTABLE '
Figure 5 . 5 Location of Bolt hole s
5- 8
CONFID ENTIAL LEVEL I- UNDER PROTECTIVE ORDER ,

BNA08758623
California, ➢b. CV 97-1554
H DMSp01659548
FASTENERS
S
ROD INSTALLATION
PUSH PULL
In push-pull rod installation, the threaded end of the rod should extend into the rod
end until at least one-half of the inspection hole in the rod end in filled . (See
Figure 5 .6 . )
MINIMUMUM OF ONE (I) FULL

PERFECT THREAD TO
REMAIN EXPOSED
Figure 5 . 6 Push Pull Rod Application
CASTELLATED NUTS
SBSUR NO
When securing castellated nuts , the center of the hole in the fastener shall not
extend beyond the end of the nut . (See Figure 5 .7 . )
ACCEPTABLE NOT ACCEPTABLE
Figure 5 . 7 Castellated Nut Applicatio n
5- 9

BNA0875862 4
H DMSp01659549
MECHANIC ' S EAND1300K
SEICIRII0 LOCK WASBIRIS
When feasible , a minimum of two tabs of a ny lock washer shall be bent over for lock-
ing purposes , one in each direction . If the tab is not at a direct right angle to
the surface over which it is to be bent, extreme care must be taken to make the bend
in the direction tending to tighten the adjustment . Backing off on the adjustment
to suit the tabs is not permitted . Installation is illustrated in Figure 5 .8 .
ILLUSTRATIONS SHOWN
ARE FOR RIGHT HAND THREAD ;
REVERSE PROCEDURE FOR
LEFT HAND THREAD .
•
ACCEPTABLE NOT ACCEPTABLE
Figure 5 .8 Lockwaoher Applicatio n
5-1 0

BNA0875862 5
H DMSp01659550
FASTENERS
0
COUNTOR SUNK WASHER APPLICATION
Installation of cocatersunk washer with high tensile bolt is shown in Figure 5-9-
COUNTERSUNK WASHER,
USED WITH HIGH TENSILE
BOLTS (160,000 PSI )
AND OVER .) INSTALL
WASHER WITH COUNTER
SINK ADJACENT TO BOLT
FILLET.
Figure 5 . 9 Countersunk Washer Applicatio n

•
TORQUIN G
GENERAL
Torque is a rotational force applied to bolts or coupling nuts to produce tension

between two connecting elements . Proper torque produces sufficient tension in fit-
tings to produce a seal - tight joint . The tension force created by torquing must be
greater than the forces produced by fluid pressures which tend to separate the ele-
ments . In addition , tension forces created by torquing must be sufficient to conform
the mating surfaces into close contact to prevent fluid leakage .
TORQUING TUBS FITTREGS
Torque values listed on the drawing or work order should be used . The torque values
listed in Figure 5 .10 and 5 .11 should be utilized in all cases not covered by speci-
fic drawings or work orders .
The correct torquing procedure is to initially torque to the values listed in Figure
5 .10 and retorque to the awe values 15 minutes after initially torquing and leak
check the system .
The torque values given are based upon the presence of a smooth , scratch free uni-
form, tubing flare . See Section 10 for instructions in preparing a flare .
5-11

BNA0875862 6
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DIEGHANIG I s HANDBOO K
FLARED TUBE "B" NUT TORQUE VALUES IN INCH-POUNDS*

is
Tube 6061-o and Stainless (CRES )

0 .D . 5052-0 Al, Alloy 6061-T6 AL Alloy Tubing Steel Tubing
Inches Tubin g
Min . Max . Min . Max . Min . Max .
l/8 20 25
3/16 25 35 30 70
1/4 40 65 70 80 300 360

5/16 60 80 70 12 0
3/8 75 125 130 180 600 740

1/2 150 250 300 400 830 1020
5/8 200 350 430 550 1230 151 0
3/4 300 500 650 800 1660 2040
500 700 goo 1100 2070 2530
1-1/4 600 900 1200 1450 2230 2730
1-1/2 600 900 1550 1850 4750 4850

1-3/4 700 1000 2000 2350 4750 4850
2 800 1100 2500 2900 4750 4850
*For combinations of tempers or materials use the applic able values shown for th e
atarial of the tubing flar e Where aluminum alloy cut e or fittings are used wit h
steel tubing, torque values for 6061-T6 tubing shall ap p ly . •
Figure 5 .10 Flared Tube "B" Nut Torque Value s
5-1 2 •
CONFTDF.NTTAT . T,F.VF.T, T- 11NDF.R PROTF.CTTVF. ORDER ,

BNA0875862 7
H DMSp01659552
FASTENU1S
•
RECOMM ED TORQUE VALUES (IN INCH/LBS)
For Jam Nuts and

For Gasketed Alum or Steel Fittings'" Fittings Without Gasket s
Fittin g
Nom . Tube Thread AN924 Net AN814 AN6289 Alum inum Stee l
O .D . Size AN815 Union Plug Nut (Lb . In.) (Lb .In . )
Min . Max . Min . Max . Min . Max . Min . Max . Min . Max .
1/8 5/16-24 25 35 10 16 25 35 35 50 -- --
3/16 3/8 -24 50 75 30 40 50 75 65 so 70 90
1/4 7/16-20 55 80 40 65 75 100 90 105 110 130
5/16 1/2 -20 75 100 60 80 90 120 105 125 140 160
3/8 9/16-18 100 150 80 120 150 200 125 145 225 275
1/2 3/4 -16 180 230 150 200 200 250 240 280 400 450
5/8 7/8 -14 250 350 200 350 275 400 330 370 550 65 0
3/4 1_1/16-12 420 600 300 500 450 650 540 660 800 960
1 1-5/16-12 600 840 450 600 650 900 840 960 1000 1200
1-1/4 1-5/8 -12 720 960 600 720 800 1000 960 1200 -- --
1-1/2 1-7/8 -12 940 1080 600 800 900 1100 1200 1440 -- --
• ,"or use with 0-rings and aluminum , asbestos , leather, tefl on , et c ., gaskets or
washers .
-For combinations of material s ( either jam nut, fitting, or boss ) use the lowest
applicable values shown .
Figure 5 . 11 Recommended Torque Values for Tube Fitting s
5-1 3

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MECHANIC ' S BANDBOOI
TORQIJDSI FLANGED FITTINGS •

Torquing Metho d
Torquing of multibolt applications of bolted flanges or any bolted joint to apply an

evenly distributed axial load to seals , gaskets, etc . shall use a bolt cross - torquing
procedure as outlined below : This procedure shall be used where a definite method of
torquing is not shown on the drawing , and may be used regardless of the number of
bolts used in the joint .
Cross torque all bolts following a numerical sequence similar to the patterns shown
in Figure 5 .12 and continue as shown until all bolts are-torqued to one third of the
total torque to be applied . Repeat this procedure torquing the bolts in one-third
increments until the total specified torque is obtained .
EVEN NUMBER OF FASTENERS ODD NUMBER OF FASTENERS
•
SINGLE ROW SINGLE ROW
MULTIPLE ROW MULTIPLE ROW
Figure 5 .12 Method of Crone Torquing
•
5-14
CDNFH)F,NFTAT, l,FXET, T - 11NDF. R PROTF.CTTVF. ORDER ,

BNA0875862 9
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FASTENERS
•
Torque Value s
Torque values listed on the engineering drawing, IRE or specification must be used .
The total installation bolt force most be great enough to properly seat the gasket .
This force comes from the actual tightening of the bolts and is not a design valua .
As an example , the ASME Code for Unfired Pressure Vessels gives design bolt stress
values ranging from 7000 to 20, 000 psi depending on the bolt material . In actual
practice the bolts are s tressed on installation from 15,000 to 60,000 psi depending
on the size of bolt and method of tightening .
The ASME Code procedures take into account the operating temperature while gaskets
are installed at ambient temperature . A design s tr ess of 20,000 psi does not allow
for joint stress decay at operating temperature . At installation the bolts are
actually s tr essed to a much higher value . As the equipment goes into operation,
stress decay takes place , and the installation bolt stress drop . off towards the
design value .
The following torque values may be used where the torque is not specified :
1 . Aircraft Type Nuts and Bolts - Use values listed in Figures 5 .13 and 5 .14
2 . Standard ASA and Grayloc High Pressure Carbon Steel Systems - The ASTM 193
bolt-stud and ASTM 194 out combination is recommended . Stress in bolts for
various loadings is tabulated in Figure 5 .15 . These values are for lubri-
cated bolts (non-lubricated bolts have an efficiency of approximately 50
percent of well lubricated bolts ) . Where possible , it is recommended that
the initial bolt stress be approximat e
3 . Machine Bolts and Cold Rolled Steel Stud Bolts - Values listed in Figure
• 5 .16 are for lubricated bolts .
4 . Stainless Steel Standard ASA and Orayloc flange bolts should be torqued
from 15,000 to 20,000 psi tensile stress .
5-1 5

BNA08758630
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Torque Values in ]noh-0unoes ( 1) for Tightening Nuts (2) (3 )
Bol t
Torque Values For
Stud
Shear Bolts Torque Values for Tensile Bolt s
or
Screw 55,000 To 90, 000 psi 55,000 To 90,000 To 125,000 To 160,000 ps i
Size 89 , 000 psi and Up 89,000 psi 124,000 psi 159,000 psi and Up
0-80 2 - 2.5 5 - 6 3 .5- 4 .5 8 - 10 10 .5- 13 14 .5- 1 8

1-72 4 - 5 9 .5-12 6 .5- 8 .5 15 .5- 20 20 - 25 .5 28 - 35 . 5
2-56 . 6 - 7 .5 14 -17 .5 10 -12 .5 23 .5- 29 30 - 37 .5 41 .5- 5 2
2-64 7 - 8.5 16 -20 .5 11 .5-14 .5 26 .4- 34 34 .5- 43 .5 47 .5- 60 . 5
3-48 9 -11 .5 21 .5-26 .5 15 .5-19 35 .5- 44 .5 46 - 57 63 .5- 79. 5
3-56 10 .5-13 .5 24.5-31 .5 17 .5-22 .5 41 - 52 53 - 67 73 .5- 93
4-40 13 -16- 30 -37 21 .5-26 .5 50 - 61 .5 64 - 79 .5 89 -11 0
4-48 15 -19 35 .5-44 .5 25 -32 59 - 74 .5 75 .5- 95 .5 105 -133

5-40 19 -24 45 -56 .5 32 -40 75 - 94 96 .5-120 .5 133 .5-167 . 5
5-44 21 .5-27 50 -63 35 .5-45 83 -105 .5 106 .5-135 . 5 148 -188
6-32 24 -29 .5 56 -69 40 -49 .5 93 -115 120 -148 166 .5-205 . 5
6-40 29 -36 .5 67 .5-B5 .5 48 -61 112 .5-142 .5 144 .5-183 .5 201 -255
NOTES : (1) To obtain values in inch pounds , divide inch-ounce values by 16 .
(2) When it is necessary to tighten the fastener from the head aide , the torque shall be within ±10 percent
of the high side of the selected torque range listed in Table I , unless otherwise shown on the drawing .
(3) Maximum torque values are to be used oonlg when materials and surfaces being fastened together hav e
sufficient area, thickness , or streng resist breaking , warping or other damage ; e .g ., no attempt
should be made to reach the maximum torque value when bolting through very thin sections of glass,
plastic or metal .
Figure 5 .13 Torque Values for Tightening Nuts
40
• • •
Data for Use With ASTM A193 Bolt-Stud and ASTM 193 Nut Combinatio n
Load in Pounds on Stud Bolts when Torque Loads are Applied
Nominal Number Diameter Area Stres s

Diameter of at Root of at Root o f
30,000 psi 45,000 psi 60, 000 ps i
of Bolt Threads Thread Thread
Torque Compress ion Torque Compression Torque Compressio n
Inches per Inch Inches Sq Inch Ft Lbs Lbs Ft Lbs Lbs Ft Lbs Lb s
1/4 20 .185 .027 4 810 6 1215 8 1620

5/16 18 .240 .045 8 1350 12 2025 16 2700
3/8 16 .294 .068 12 . 2040 18 3060 24 4080
7/16 14 .345 .093 20 2790 30 4185 Co 5580
1/2 13 .400 .126 30' 3780 45 5670 60 7560
9/16 12 .454 .162 45 4860 68 7290 90 9720
5/8 11 .507 .202 60 6060 90 9090 120 12120
3/4 10 .620 .302 100 9060 150 13590 200 1812 0
7/8 9 .731 .419 160 12570 240 18855 320 2514 0
8 .838 .551 245 16530 368 24795 490 3306 0
1-1/8 8 .963 .728 355 21840 533 32760 710 4368 0

1-1/4 8 1 .088 .929 500 27870 750 41805 1000 5574 0
1-3/8 8 1 .213 1 .155 680 34650 1020 51975 1360 6930 0
1-1/2 8 1 .338 1 .405 800 42150 1200 63225 1600 8430 0
1-5/8 8 1 .463 1 .680 1100 50400 1650 75600 2200 10080 0

1-3/4 8 1 .588 1 .980 1500 59400 2250 89100 3000 11880 0
1-7/8 8 1 .713 2 .304 2000 69120 3000 103680 4000 13824 0
2 8 1 .838 2 .652 2200 79560 3300 119340 4400 15912 0
2-1/4 8 2 .088 3 .423 3180 102690 4770 154035 6360 20538 0

2-1/2 8 2 .338 4 .292 4400 128760 6600 193140 8800 25752 0
2-3/4 8 2 .588 5 .259 5920 157770 8880 236655 11840 31551, 0
3 8 2 .838 6 .324 7720 189720 11580 284580 154,10 37944 0
Figure 5 .16 Torque Values for ASTN 193 and ASTM A194 Nut and Bolt Combinations
b
MECHINIC ' s HANDBOOK
TORQUE WBENCHIR AND THEIR USE
several torque wrench types are shown in Figure 5 .17 . Their use and limitations are :
1 . Research has .proved that it is physically impossible for any mechanic t o

tighten a l of nuts or bolts to an equalised pre-determined tension
with ordinary wrench equipment .
2 . Torque wrenches are precision tools ; they should not be subjected to abuse
or misuse .
3 . Do not put the torque wrench at the bottom of your tool chest and pile
tools on top of it . A special storage place is supplied for it; always
put it there when you are finished with it .
4 . Never use a torque wrench to break nuts loose . It is not a working wrench
but a precision tool used to obtain accurate measuring .
5 . Torque readings should be taken only while tightening the fastener . Do not
overtighten and then loosen to the desired torque value .
6 . Never jerk a torque wrench . Force most be applied slowly for an accurate
indication of the torque being applied to a fastener .
7. no not attempt to use a torque wrench to tighten a fastener to a higher

value than the maximum value shown on the torque wrench indicator .
8 . All bolts and studs should be cleaned thoroughly before being tightened .
The "thread drag " caused by rusted or dirty threads makes it impossible
to torque accurately .
9. Sockets and/or adapters must be installed fully on the nut or bolt . Main- •
taining a slight inload on the wrench will lessen the chances of damage to
the fastener .
10 . All torque wrenches must receive a periodic calibration to compensate for

wear , and should not be used after the void date shown on each wrench .
•
5-20
CONFTDF.NTTAT . T,F.VF.T, T - UNDER PROTECTIVE ORDER ,

BNA0875863 3
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• • •
Bolt, ( 4) Shear Type Bolt ,

Torque Values for Tensile Fasteners
Stud Nuts Stu d
or 125,000 psi 55,000 to 90,000 to 125,000 to 160,000 psi or
Screw and U 89,000 psi 124,000 psi 159,000 psi and Up Screw
Size n .- Ft-Lb In .-Lb Ft-Lb In .-Lb t- In .-Lb Ft-Lb n .- b Ft-Lb Siz e
8-32 8- 11 11- 14 14- 18 19- 24 0-32

8-36 9- 12 12- 15 1620 22- 28 8-36
(1) (1)
10-24 12- 15 15- 19 20- 25 28- 35 10-24
10-32 14- 18 19- 24 24- 30 33- 42 10-32
1/4-20 31- 39 40- 50 52- 65 72- 90 1/4-20
1/4-28 36- 47 (5) (5) .47- 61 (5) 61- 75 (5 ) 85- 110 (3) 1/4-28
5/16-18 63- 80 80- 105 105- 135 145- 180 5/16-18
5/16-24 71- 90 90- 120 120- 155 16o- 210 5/16-24
3/8-16 110- 140 62- 80 145- 180 180 - 230 250 - 330 3/8-1 6
3/8-24 125- 160 70- 90 16o- 210 210- 280 290- 390 3/8-24
7/16-14 180- 230 100- 130 230- 300 300- 380 420- 530 7/16-1 4
7/16-20 200- 260 110 - 145 250- 330 330- 430 460- 600 35 50 7/16-20
1/2-13 270- 350 150- 190 350- 450 450- 580 630- 810 50 65 1/2-1 3
1/2-20 310- 410 170- 230 400- 530 520- 680 40 55 720- 950 60 80 1/2-20
9/16-12 400- 510 220- 290 520- 670 40 55 670- 860 55 70 920-1190 75 100 9/16-12
9/16-18 450- 590 250- 330 580- 770 45 65 750- 990 60 80 1040-1380 85 115 9/16-1 8
5/8-11 550- 700 300 - 390 710- 910 60 75 910-1180 75 95 1270-1630 105 135 5/8-1 1
5/8-18 620- 830 50- 70 350- 460 810-1070 65 90 1040-1380 85 115 1450-1920 120 160 5/8-1 8
3/4-10 960- 1240 80-100 530- 690 1250-1610 105 135 1600-2080 130 170 185 240 3/4-10
3/4-16 1080-1430 90-120 600- 790 50 65 1400-1850 115 155 150 195 200 270 3/4-l'6
7/8-14 140-190 960-1270 80 105 . 185 240 240 310 330 440 7/8-1 4
1-12 210-290 1450 -1930 120 160 280 370 360 480 500 670 1-1 2
1-14 210-290 1460-1960 120 160 . 280 380 360 490 500 680 1-1 4
1-1/8-12 310-410 170 230 400 540 520 690 720 960 1-1/8-1 2
1-1/4-12 430- 580 240 320 560 750 720 970 1000 1350 1-1/4-1 2
NOTES : To obtain value in foot pounds, divide inch-pound values by 12 .

(21 When nuts are to be secured with cotter pins or lockwire, tighten the nut to the low side of the selected torque
range and if necessary continue tightening until the next slot aligns with the hole . Nuts shall not be backed off
to obtain alignment .
(3) When it is necessary to tighten the fastener from the head side, the torque shall be within ±10 percent of the
high aide of the selected torque range unless shown on the drawing .
4 Values to be used with nuts designated as shear type nuts .
5 Recommend use of wrenches graduated in inch-pounds for these fasteners .
6 Above values apply only at ambient temperatures of -65 F through 165 F.
-1 Figure 5 .14 Torque Values for Tensile Fasteners

Data for Use With Machine Bolts and Cold Rolled Steel Stud Bolt s
Load in pounds on Bolts and Stud Bolts when Torque Loads are Applied
Nominal Number Diameter Area Stres s

Diameter of at Root o f at Boot o f
of bolt Threads Thread 7,500 psi 15,000 psi 30,000 P e i
Thread
Torque Compression Torque Compression Torque Compressio n
Inches per Inch Inches Sq Inch Ft Lba Lbs Ft Lbs Lba Ft Lbs Lba
1/4 20 .185 .027 1 203 2 405 4 81 0
5/16 18 .240 .045 2 338 4 675 8 135 0
3/8 16 .294 .068 3 510 6 1020 12 204 0
7/16 . 14 .345 .093 5 698 10 1395 20 2790
1/2 13 .400 .126 8 945 15 1890 30 378 0
9/16 12 .454 .162 12 1215 23 2430 45 486 0

5/8 11 .507 .202 15 1515 30 3030 60 606 0
3/4 10 620 .302 25 2265 50 4530 100 9060
7/8 9 .731 .419 40 3143 80 6285 160 12570
1 8 .838 .551 62 4133 123 8265 245,' 1653 0
1-1/8 7 .939 .693 98 5190 195 10380 390 2076 0
1-1/4 7 1 .064 .890 137 6675 273 13350 2670 0
545
1-3/8 6 1 .158 1 .054 183 7905 365 15810 730 3162 0
1-1/2 6 1 .283 1 .294 219 9705 437 19410 875 38820
1-5/8 5-1/2 1 .389 1 .515 300 11363 600 22725 1200 4545 0
1-3/4 5 1 .490 1 .744 390 13080 775 26160 52320
1550
1-7/8 5 1 .615 2 .049 525 15368 1050 2100
30735 6147 0
2 4-1/2 1 .711 2 .300 563 17250 1125 34500 2250 69000
Figure 5 . 15 Torque Values for MaohineBolts and Cold Rolled Steel Stud Bolt s
is
•
0
FAST N RS
• FLEXIBLE BEAM N TORQUE WRENCH FOR N SENSdR

TOQUE WRETCH UEE ON HYWNUUC LINES TORQUE WRENOI
E ORSVTNY VIM OF B RKIO FRAME TORQUE WRENCH SNOWING THE TORSION

MR MENSOMNNG ELEMENT
T
0
SNONING THE EFFECT NOM B IONGITMMN& MENSUNNG ORCNCES

OF NN EXTENSION ON EXTENSION 6 USED W. ORrvL M -E
flE
THE TQIIO{K RE .Am EXTENSION ON WRENOI
Figure 5 .17 Torque Wrenche s
5-21

BNA0875863 6
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K501ANIC ' 5 HANDBOOK
HOW ADAPTORS AFFECT TORQUE •

1 . To understand why some extensions and adaptors change or alter the torque at
a bolt, a brief explanation of what is meant by " torque " and how it is
measured should prove helpful . Theoretically , "torque" is the movement of a
system of forces around an object which tends to produce twist or torsion .
A wrench acts as a lever when force is applied , and the amount of torque
produced upon the bolt is dependent upon the length of the wrench and the
amount of force applied .
2 . In Figure 5 .18 the lever length of the wrench from the center of the not to
the center of the hand applying the force is represented by "L" . The ap-
plied force is indicated by "F" . Since torque "T !' is the product of the
applied force multiplied by the effective lever length, it can be calculated
by using the formula : T = F X L .
Figure 5 . 18 Wrench Without Adapto r
3 . Because the applied force usually is measured in pounds , while the lever
length is measured in inches or feet, the resulting torque is measured i n
och-pounds or foot-pounds . Thus if "L" is one foot and F" is 30 pounds,
T" equals 30 foot-pounds . •
"
4 . As show in the figure above , "F" must be applied at a 90 'degree angle to
the lever . When the force is applied in any other direction , a lesser
torque than that calculated is exerted by the wrench .
5. A torque wrench has a built-in device which indicates to a mechanic when

he has exerted the desired amount of torque on a bolt or nut . A reading
on a dial is made directly in foot-pounds or inch-pounds . However, when
adaptors which add lever length are used with torque wrenches, the wrench
no longer reads true, and corrections must be made .
6 . If an adaptor or extension is attached to the square drive, which changes

the length of the torque wrench, the readings on the dial will not give
the actual torque . A simple formula , however, enables one to figure out
what the dial should read for a pre-determined torque using any adaptor .
(Figure 5 .19 .)
T x L
Formula : S-
L+ E
90°
Figure 5 .19 Wrench With Adaptor Attached to Square Driv e
5-22 •

BNA0875863 7
H DMSp01659562
FASTENIES
• 7 . The letters in the formula have the following meaning : (See Figure 5 .19.)
T = Torque desired ( actual torque)
S = Dia1 reodiog . This is the unknown factor . You vent to know what it
should be when you use an adaptor .
L = Distance from the square drive of the torque wrench to the center of
the operator' s hand on the handle of the torque wrench . The pull must
be at right angles to the centerline of torque .
E = Extended length of the adaptor parallel to the handle . Measure this

from the bolt to the square drive of the torque wrench and use only
that distance which is parallel to the torque wrench.
Example : L = 12 "
s = Unknown
T = 360 in . lbs
360 1320
S = LL + EE or S = 12 x 32 = 15 = 288 in . lb s
288 12 = 2 4 It lb s
8 . The example explained above gives a very simple conversion using a straight
extension . However, there are many types of adaptors and extensions . A few
are shown in the following figures, but in each case it is obvious that only
• the added extension from the square drive of the torque wrench increasing
its length will change the readings . It is also well to note that an ex-
tension which is perpendicular to the torque wrench , regardless of length"
does not affect the readings .
9. It is difficult to get accurate readings if universal joints are used and,

therefore , an adaptor should be used instead , whenever possible . If it is
absolutely necessary to use a universal joint, the formula should he used
to figure the corrected torque .
10 . This handle extension does not affect the dial reading although it does
increase the torque . No correction is necessary because factor "E" is
not changed . (See Figure 5 .20 . )
Figure 5 .20 Adaptor Attached to Handle End of Wrench
5-23

BNA08758638
H DMSp01659563
K
MAGcINZST' S HANDBOO
11 . This adaptor doubles the length and leverage of the torque wrench . The dial
will read only 1/2 of the torque . Note "L" and "E" are equal . (See Figure
•
5 .21 .)
Figure 5.21 Adaptor Attached to Square Driv e
12 . This adaptor or wrench affects the dial reading . Factor " E" is involved and
therefore a correction is necessary . Note that "E" is not the length of the
adaptor but only the increase in length parallel to the torque wrench . (See
Figure 5 .22 . )
Figure 5 .22 Adaptor Attached to Square Drive
•
13 . Here again we have a wrench which adds length . Note that only the distance
parallel to the torque crouch is used to get Factor "E" . (See Figure 5 .23 . )
Figure 5 .23 Adaptor Attached to Square Drive
5-24 •

BNA0875863 9
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0
SECTION 6
LUBRICANTS, GAS} S, SEALS AND PACKAGING
CONTENT S
Page
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
Definitions and Functions . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Application of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Thread Lubricant Application . . .
. . . . . . . . . . .
. . . . . . 6-1
Dynamic 0-Ring Lubricant Application . . . . . . .
. . . . . . 6-2
Static Seal Lubricant Application for Greases and oils . . . . . . . 6-2
Application of Dry Powdered Lubricant (Such as Molykote Type Z Powder) . . 6-3
RB0120-017 Dispersion Application for Naflen , Flange Seals , and Washers . 6-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Gasket Types and Materials . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Boss Sealing Recommendations for Hot Gas and Cryogenic Applications . . . . 6-6
Boss Sealing Limitations for Hot Gas and Cryogenic Applications . . . . . . 6-6
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
• MS28778 0- Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
AN6227B 0- Rings (MS28775 Equivalent) . . . . . . . . . . . . . . . . . . . 6-8
AN6230B 0-Rings (MS28775 Equivalent) . . . . . . . . . . . . . . . . . . . . 6-8
Conical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Good Practice Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Items Requiring Packaging . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Packaging Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 9

BNA08758640
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LUBRICANTS, GASKETS,
SEALS AND PACEAGING
•
LUBRICANTS .
DEFINITIONS AND FUNCTIONS
The general term lubricants includes the following specific terms and functions :
1 . Lubricant . . . . . . . . . . a material used to reduce friction between

threaded devices or sliding surface s
2 . Sealant . . . . . . . . . . . a material used to effect a seal between two

surfaces
3 . Antiseize . . . . . . . . . . a material used to allow easy disassembly o f

threaded parts
4 . Thread compound . . . . . . . a compound used with NPT joints to perform the

function of sealant , lubricant , and antiseiz e
APPLICATION OF LUBRICANT S
THREAD LUBRICANT APPLICATION
Applied across the threads

(male threads only )
Figure 6 .1 Thread Lube Applicatio n
The number of application points will vary with the size of the fitting . ( See Figure
6 .2 .)
Thread Diameter , No . of Application Approx . Width of Streak ,

inch Points inch
Up to 1/2 1 1/8 to 1/4

Over 1/2 and up to 1 1 3/8
Over 1 and up to 1-3/4 2 1/2
Over 1-3/4 through 2-1/2 3 1/2
Figure 6 . 2 Lubricant Application
EXAMPLE : The illustration

shows one appli-
ation point.
(See Figure 6.i .)
6- 1

BNA08758641
H DMSp01659566
Lubricate interior and exterior thrust surface of tubing sleeve (See Figure 6 .3 )
•
Apply thin layer of

lubricant . Wipe off
excess .
INTERIOR THRUST SURFAC E
Figure 6 . 3 Lobe Application to Tube Fittings
DY.WMIC 0-RING LUBRICANT APPLICATION
1 . Pack one-quarter the distance around the groove with the required lnbricant prior
to installing the 0-ring ( see Figure 6 .4) .
PILL THIS AREA WITH PROPER LUBRICANT.

LUBRICANT SHOULD BE FLUSH WITH THE
EDGE OF THE GROOVE .
•
Figure 6 .4 Lube Application to 0-Ring Groove s
2. Spread lubricant evenly within the groove . This may be accomplished by hand o r
by installing the 0-ring and then rotating it several times around the groove .
3. Additional lubricant may be applied to the mating surface . Globules of grease

on the mating surface must be wiped off .
4. 0-ring lubrication for hydraulic fluid or oil should be accomplished by dippin g

the O-ring in the fluid before installation .
STATIC SEAL LUBRICANT APPLICATION FOR GREASES AND OIL S
1 . Apply lubricant 'to dry static 0-rings . Distribute uniformly over the surface of
the 0-ring and remove excess by drawing the 0 -ring through the finger tips .
2 . If lubricating material is needed to retain a static 0 -ring in its gr oove while

installing a mating part, the amount of material should not exceed 10 percent of
the total volume of the gr oove .
3• Flat seals used between flat surfaces without grooves should be coated on both
sides with the sealing compound .
•
6-2
CDNFID ENTL&L LEVEL I- UNDER PROTECTIVE ORDER ,

BNA0875864 2
H D M Sp01659567
LUBHICANPS , GASKETS ,
SEALS AND PACKAGING
• Johns -Manville A general use sheet gasket of rubber compound and asbesto s
(Number 76 ) composition . Will handle Kerosene , water and LN2 .
Vellumoid A brown paper - like material used in gaseous and fue l

service .
Teflon Polytetrafluoroethyleae sheet suitable for gasketing i

applications from -423 F for extended periods of time . n
Suitable for use with LOX, hydrogen peroxide (B2O2) ,
alcohol, and other fluids . Extensively used for soft coats
in valves . It has limited flexibility at LOX temperatures .
Teflon gaskets tend to extrude if overtightened . Teflo n
forms toxic vapors when bu rn ed .
Kel-F An expensive , partially chlorinated fluorocarbon gaske t

material for use from - 423 to 390 F. Suitable for sam e
use as Teflon , but with better flexibility at low temper -
atures . Kel -F forms toxic vapors when burned .
Spiral Wound Gaskets A ve ry strong high pressure gasket composed of alternat e

bands of stainless steel and Teflon, Kel -F, or asbestos .
Metallic Gaskets Manufactured of various metals for such high temperature

and pressure uses as turbine exhausts . Usually soft copper
with or without a chrome plating .
Flurogold ( or) Same general characteristics as Teflon except it has glas s

Flurogreen fiber strands incorporated for strength and reduced cold
• flow properties .
Figure 6 . 5 Flat Gaskets in Use at the Field Laboratorie s

Comments :
1 . Do not use serrated flange surfaces against spiral wound gaskets .
2 . Use Flurogold ( glass filled Teflon) wherever possible for LH2 systems baying
concentric serrated flanges .
3 . Bolts must be cross torqued to effect even gasket loading and to prevent over-
compression of gasket sections .
4 . Bolts most be torqued to values specified for proper gasket loading .
5 . Gaskets most comply with designer or manufacturer's standards . Gaskets not in

compliance due to previous installation shall not be used . Substitutes will not
be made without proper engineering consideration .
•
6- 5

BNA08758643
H DMSp01659568
SEAL S
BOSS SEALDAI RECOlfENDATIONS FOR HOT GAS AND CRYOGENIC APPLICATIONS
The following seals are recommended in a preferred order :
1. Temperature range 500 to 1000 F :
a. NATORQ P /N VD261-0123 -J000C (silver plated )
b. Harrison "K" P/N 12100 AA (gold plated )
2 . Temperature range -423 to 500 F :
a, Harrison "K" P/N 12100 CR (Teflon coated )
b. NATORQ P/N VD261-0123 - XXXI
3 . All service bulkhead application :
a . NATORO 1111261-0006 - 1L47Q1
4. Transducer applications limited to low torque values and high temperature :
a . Harrison "K" P/N 12100 AA (gold plated )
5. Transducer applications limited to low torque values and c ryogenic temperature :
a . Harrison "K" P/N 12100 CR (Teflon coated) •
BOSS SEALING LIMITATIONS FOR HOT GAS AND CRYOGENIC APPLICATIONS
The following limitations end recommendations are made for boss seals :
1 . Recommended increased torque values for the above seals used in copjunctioq with
standard fittings are as shown in Figure 6 .6 .
Fitting Dash Size Tube Diameter, inch In .-lb Ft-lb . )
1/4 300 25 ,
-6 3/8 600 50
1/2 840 70
-10 5/8 1250 104
-12 3/4 1680 140

-16 1 2100 175 .
I
Figure 6 . 6 Increased Torque Values for Boss Seal s
2 . Do not use AN900 series copper crush washers or AN901 series asbestos filled
copper gaskets in AN10050 boss seal applications .
3 . Do not use elastomer 0-rings above or below their rated maximum temperatures--
not even for a short time .
0
6-6
CONEIDENTTAT, T,EVET, T - ITNDER PROTECTIVE ORDER ,

BNA0875864 4
H DMSp01659569
LUBRICANTS , GASIIETS,
SEALS AND PACKAGING
S 4 . Sealant for flat mating surfaces , without a gasket type seal, should be spread
uniformly on both surfaces . Wipe off excess prior to joining the parts .
5- Flexitallic gaskets should be thoroughly wetted on both sides with the sealing
compound . Sealant should be worked into the gasket grooves with moderate finger
pressure .
APPLICATION OF DRY POWDERED LUBRICANT (st N AS MOLYKOTE TYPE Z POWDER)
1 . Metal parts must be vapor degreased .
2 . Nonmetallic parts must be cleaned by immersion in 550210-005 or 0.50210-002 mild

alkaline cleaning solution .
3 . Parts should not be touched by bare fingers after cleaning . Clean cotton gloves
should be worn .
4 . Dry powdered lubricants should be applied as soon as possible after cleaning .
5 . Lubricant should be rubbed onto the surface to be lubricated with a clean, lint-
free nylon cloth .
6 . Excess lubricant should be removed :
7 . Sliding surfaces should be thoroughly coated during installation .
550120-017 DISPERSION APPLICATION FOR NAFLEX , FLANGE S0AIS , AND WASHERS
• 1 . Dispersion must be mixed prior to use .
2. Drawings should specify the method of application .
Application Method I
1 . Apply with lint-free nylon cloth or nylon brush to the sealing

surfaces of the grooves or flanges .
2 . Use a light touch, applying in one coatimuous stroke .
3 . Allow to dry for 5 to 7 minutes .
4 . Apply a second soot.
5 . Immediately install seal or washer and assemble while the dispersion

is still damp .
Application Method I I
1 . Follow the same procedure as for method I, except apply the dispersion
only to the gasket , seal, or washer rather than the groove , flange ,
or mating surfaces .
Application Method II I
1 . Follow the procedure for method I, except apply dispersion to all

contacting surfaces . Use only one coat.
6- 3

BNAU8758645
H DMSp01659570
MECHANIC'S HANDBOOK
•
GASKETS
GASKET TYPES AND MATE[11ALS
General
Application of gaskets depends on three main factors : compatibility of the gasket

material with the fluid, ability to withstand the pressure temperature system and
the relationship of total installation bolt force to gasket seating stress and hydro-
static end force .
Flat Gaskets
Several types of flat gaskets and their limitations are listed in figure 6 .5•
Ring Joint Gasket s
These gaskets are available in the oval or octagonal cross-section . They are made
of soft carbon steel or stainless steel . High pressure gas and cryogenic systems
are equipped with this type gasket .
Pressure-Energized Gasket s
The Naflex and Pneuflex seals are the two common gaskets in use at the Field Lab-
oratories . Since the fluid pressure tends to provide the seal, only light bolt
loads are required . Metallic pressure-energized seals have a "U" shaped cross-
section with relatively flexible members that are deformed by the flange . The fluid
pressure inside the "U" acts on the flexible member to produce a contact stress at
the seal contact interface . •
Because of the relatively high cost and the surface finish requirement it is essen-
tial that cleanliness and careful handling be exercised with this type seal .
NOTE : All gasket types should be carefully handled to prevent damage to sealing
surfaces . Most gaskets depend om a hair line seal and only a slight scratch
or nick may cause leakage . -
6- k

BNAU8758646
H DMSp01659571
LUBRICANTS , GASKETS,
SEALS AND PACKAGING
• 4 . In applications where Photocon transducers are applied in AN10050 threaded boss

ports, the torque requirements are limited by the transducer and must comply to
the manufaetsrer ' s recommendations .
5 . Boss seals should never be reused unless they can be leak-checked per system
pressure requirements . Retorquing is permissible provided that the seal fitting
combination has not been subjected to zero torque conditions , which disrupts the
original continuity between the contacting surfaces . In this situation, leek-
check after retorquing .
6. The use of bulkhead fittings i not recommended for high temperature or cryogenic
applications ; however , in special installations where bulkhead fittings must be
incorporated , elastomer 0-rings should be replaced with metal NATOR9 bulkhead
seals, VD261-0006-XXXX ,
7 . Teflon 0 - rings are not recommended for cryogenic or high temperature applications .
The cold flow properties of Teflon combined with a noscaptivating seal cavity
will allow the initial seal preloading to relax .
0-RINGS
General
1 . Used as moving and nonmoving seals .
2 . Manufactured in many different sizes and from a variety of materials .
3 . Must be compatible with system fluids and pressures .
4 . In general, different types of 0-rings are not interchangeable .
5 . 21528778, AN6227B, and 1016230 0-rings are stocked at the field laboratories .
•
6 . Bung-N 0-rings are not suitable for use at cryogenic temperatures .
7 . Beware of 0-ring shelf life . Do not use outdated materials .
11828778 0-Ring s
21528778 (Gasket-straight thread tube fitting, boss) 0-rings are required for gasket
applications on A2Dl0056 and A21210057 straight thread tube fittings in AND10050
bosses for port connections of pumps, valves, end other units in hydraulic and pneu-
matic systems (see MIL-6-5510) . They are also used with three-piece tube fittings
for mounting in straight thread bosses .
11528778 0- ring sizes are indicated by dash numbers which refer to tubing size in
1/16-inch increments . For example, tubing measuring 1/4 inch uses a Dash-4 fitting
which requires a Dash -4 0-ring .
Although MS28778 and 1216227B 0-rings are apparently the same, they are not inter-
changeable . A216290 0-ring dash numbers are not comparable to 10f6227B 0-ring dash
numbers .
MS28778 O-rings are supplied in Buna-N material and are identified by a 1/32-inch-
wide nonpermanent blue stripe around the outer circumference .
Installation of an 0-ring with a fitting requires the fitting to have a hex shoulder
of sufficient width to cover the entire 0-ring . Some AN fittings are not suitable
for use with 0-rings . For use with AND10057 bulkhead flared tube connections in
pneumatic or hydraulic systems to 3000 psi, the installation required an 1016289 nut
and an 1016291 leather ring . For use in fuel systems, an 121924 nut is used in lieu
of an A016289 nut and 1216291 leather rings .
b-7

BNAU8758647
H DMSp01659572
MECHANIC~s HANDBOOK
AN6227B O-Ringo (M52s775 Equivalent) •
.0116227E 0-rings ( Packing 0-ring hydraulic ) are designed for hydraulic service (ref .
MI1 -F-5516) . They are suitable for moving or nonmoving seala . The usual application
is with hydraulic pistons, valve stems, or other installations involving recipro-
cating , rotary, or oscillating movement . Provisions moat be made for lubrication
when they are metalled as moving seals in pneumatic systems . .01162278 0-rings are
not designed for use with fittings .
These 0-rings are furnished in a rasge of various erase-section widthg and diameter
sixes to fit standard 0-ring gland dimensions per MIIrP-5514 . For use with pressures
from 1500- 3000 psi, the gland desige has provisions for backup rings of leather, Tef-
lon, Kel-F, or other materials to prevent extrusion of the 0-ring . A116227B dash nine-
hers do not represent size increments but must be chosen according to the required ID
and the cross- sectional width of the groove dimension .
AN62270 0- ringa can be identified by two or three oolored data on the outer diameter,
the number sod color of the dots varying between manufacturers . They are supplied in
Buae a-N material .
Rectangular grooves as established in MIL-P-5514 must be used for .01162278 0-ring

installation . Care most be taken not to scratch or nick the 0-ring . Lubrication
compatible to the system should be employed . 11N6227B 0-rings are not dimensionally
the ammo as 0156290 0-rings in comparable sizes, and .01162278 0-rings are not accept-
able subatitntes for 1016290 0-rings in tube fitting applications . .0162270 0-rings
require A116216 backup rings for pressurea from 1500 to 3000 psi .
A0162308 0-Rings (010128775 Equivalent )
AN62308 0- rings (Gasket 0-ring hydraulic ) are designed for nonmoving gasket applica-
tions in hydraulic service (MIL-P-5516) . This 0-ring is comparable to .01162278 but •
is limiied to static applications . It is furnished in ID dimenaions of 1-5/8 inch
through 4-5/ 0 inches an d is available only in a 1 /S-inch cross -section size . A1162300
dash numbers are not comparable to .01162278 or .0016290 dash numbers .
Installation of AN62300 0-rings is the same as .0062278 0- rings except that for pres-
sures from 1500 to 3000 psi the A016230B 0-ring requires an A116244 backup ring .
Conical Seal s
It is necessary to utilize an annealed copper conical seal in Facility tubing connee-

tisus ( 1/4 inch size optional ) to insure s leak-free connection . (See Figure 6 .7 . )
Figure 6 .7 Typical Conical Seal

•
6- 8
CDNEIDENTL&L LEVEL I- UNDER PROTECTIVE ORDER ,

BNA0875864 8
H DMSp01659573
LUBRICANTS , GASKETS,
SEALS AND PACKAGING
GOOD PRACTICE TIPS
1 . Do not use a lubricant if doubt eriato concerning its compatibility in the system .
2 . Lubricants - must be compatible with all downstream materials in fluid systems .
3. Lubricants contaminated with dirt , grit , metal chips, or other foreign matter
must be discarded .
Doe lubricants from original marked cans only . Do not return excess to the con-
tainer .
5. Some lubricants have a shelf life . De aware of the date on the container .
6. Avoid excessive lubrication . Lubricants should be applied in a streak across

male threads . The amount of lubricant depends on thread size . Follow applica-
tion procedures in the appropriate process specification .
7 . Do not lubricate female threads or flares . Interior and exterior thrust surfaces
of the tubing sleeve must be lightly lubricated to prevent galling during torqu-
ing of B-nuts .
Do not apply lmhricnnt to the end of a fitting .
PACKAGING
ITEMS 11EQOIRINl PACKAGING
• When components are fragile , have an irregular configuration or sharp projections,

have a close tolerance on surface finishes or surface flatness or total alignment .
and/or have a weight in excess of one pound additional physical protection to the
bagged or capped component may be required . Packaging should be indicated on the
drawing , specification or engineering work request .
PACKAGING METBOD S
Where specific requirements are sot called out on the controlling document the fol-
lowing methods are recommended :
1 . Package the component in a container selected so the component will not

occupy more than three- fourths of any container dimension . Locate the com-
ponent centrally within the container .
2 . for a suitable alternate , the componeat may be wrapped with a cushioning

material Pigure 6 .8. Cushioned items should be packaged in a suitable snug-
fitting, rigid or semi-rigid container . Oversized containers may be used
when additional cushioning materials are used to prevent movement of the
component within the container .
•
6- 9
CDNFfDF.nTTAl, l,FXF, l, l- i7NDF. R PROTF.CTTVF. ORDER ,

BNA0875864 9
H DMSp01659574
tdFCEANIC' S MAM)BOOK
SELECTION OF CUSHION WRAP MATOEIALS •

(Minimum Thickness , Inches )
Part Weight , lbs Polyurethane Foam Polyethylene Foam
Less thus 7 1/2 1/8
7 to 10 1 1/4
1o to 15 - 3/8
15 to 20 - 1/2
NOTE : Sheets of different thicknesses may be combined to obtain th e

required thickness .
Figure 6 . 8 Selection of Cushion Wrap Materials
•
6-1 0
CONPTDTNTIAI, I,TVTI, I- ITNDTR PROTECTIVE O lt I)PR ,

BNA0875865 0
Cslifornia, No. CV 97-1554
H DMSp01659575
I
SECTION
LIQUID PROPELLANTS , PRESSURANTS
AND SOLVENTS
CONTENTS
Page
Liquid Propellant Definitions 7-1
Liquid Propellant , Pressurant , and Solvent Data 7-5
Compatible Materials to be Used in Systems . . . . . . . . . . . . . . . . . 7-9
Safety Clothing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
First Aid Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Fire Control Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 5
•
NOTES :
1 . The engineering work order , drawing, or the latest process specifica-

tions should be consulted prior to the selection of compatible materials
(metals, nonmetals , and lubricants to be used in a propellant system .
2 . The safety clothing data for propellant handling is subject to revision

at any time . Your supervision will notify you of any change .
• 1

BNAU8758651
H DMSp01659576
LIQUID PROPELLANTS
PRESSURANTS AND SOLUINTS
•
LIQUID PROPELLANT DEF INITIONS
Ambient
Condition of surrounding area. Thus ambient temperature or pressure is the pre-

ailing temperature or pressure surrounding the object in question, usually room
conditions .
Anhydrou s
Free of water . ,
Atmosphere
A unit of pressure equal to 14 .7 psi at sea level .
Auto - Ignition Temperatur e
The lowest temperature at which a substance in contact with air ( or other oxi-
dizer if specified) will ignite spontaneously and continue to support combustion .
Bo line Poin t
The temperature at which the vapor pressure of a liquid becomes equal to the
pressure of the ambient atmosphere . Boiling point varies with the pressure of
the liquid .
Catalyst or Catalytic Agen t
Any substance which, by virtue of its presence , affects the rate of a chemical
reaction and which may be recovered practically unchanged at the end of the
reaction .
•
Compatible
Saving no undesirable effect with or upon another material under specified con-
ditions of use.
Corrosive
A material which acts upon another material in such a way as to destroy or dam-
age it permanently . Example : Acid destruction of the interior of a pipe or
tubing installation .
Critical Pressure
The existing pressure at the critical temperature .
Critical Temperature
The highest temperature at which a gas can be liquified without regard to the
pressure applied .
Cryogenic Temperature
A material whose upper limit of the critical temperature is -238 F (-15o C) or

colder .
Decomposition
Separation of a propellant or solvent into two or more substances which can

cause a rapid rise in-system pressure .
7-1

BNAU8758652
H DMSp01659577
MECHANIC' S ItOIWBOOlt
Density
•
Conceotration of material either liquid or solid , measured by the weight per unit
volume .
Disc ti l c
Able to stand deformation under a load without fracture . Also, pliant or flexi-
ble . In rocket testing we arc concerned with the ability of certain materials to
remain pliant or flexible at test temperatures .
Flammabl e
Combustible . A material which can be ignited .
Flammable Limits, Upper and Lowe r

Limits established by tilt richest and leanest mixtures of flammable gas and air
that viii support flame propagation upon ignition . They are expressed in terms
of percentages of gas or vapor in air by volume ( e .g ., the flammable limits of
gasoline ore 6 percent to 1 percent and mixtures beyond these limits are too rich
or too lean respectively, to support flame propagation) .
Plash Point
The minimum temperature at which the surface of a liquid may be momentarily

ignited by an open flame .
Freezing Point
The temperature at which a material changes from a liquid state to a solid state .
The freezing point is slightly dependent upon pressure .
Fuel
•
Any combustible material which can burn with an oxidizer .
IIvgroscopic
Capable of absorbing moisture from the air .
Ilvaergol i s
A term applied to describe self-ignition of a fuel and oxidizer upon contact with
each other .
Imaerv i ous
Impenetrable ; pertaining to clothing which may be impenetrable to certain fluids,

chemicals, etc .
Inert
Incapable of producing a reaction . A material which will not burn or support

combustion .
Inhibit
To check or retard a chemical action .
Liquid Propellan t
A chemical in liquid form used as a fuel, oxidizer, or monopropellant to provide
the combustion necessary for the production of thrust by a rocket engine .
7- 2
CDNPIDENTL&L LEVEL I - UNDER PROTECTIVE ORDER ,

BNA08758653
H DMSp01659578
LIQULD PROPELLANTS,
PRESSOJOANTS AND SOLVENTS
Liquid to Gas Rati o
A comparison of the volume of the liquid state of a material at its boiling

point, to the volume of its gaseous state at standard temperature and pressure
(59 F and 14 .7 psia) . Example : 1 cubic foot of liquid oxygen, at its boiling
point, will evaporate into 862 cubic feet of gaseous oxygen at 59 F and one
atmosphere . Therefore , the liquid to gas ratio is L862 .
Maximum Allowable Concentratio n
The maximum amount of a toxic gas or vapor that the body can stand for an 8-hour
period in one day, for as indefinite number of days, without causing any effect
to health . It is expressed in parts per million (ppm), by volume, of the gas or
vapor in air . The majority of rocket propellants are toxic by naure .
Monooropellant
A single material , usually utilized with a catalyst to cause it to react for pur-
poses of powering a rocket engine or some component thereof .
Oxidizers ( or Oxidizing Agents )

A chemical that will actively support combustion or oxidation of a fuel .
Padding ( or Blanketing )
Filling the void or ullage of a closed container with an inert gas ( usually
nitrogen ) to prevent oxidation of the chemical contained therein, and to avoid
the formation of flammable or explosive mixtures by excluding air from the con-
tainer .
Passivation
•
The treatment of metals to render them inert to the action of a particular cliemi-
cal or mixture by the formation of an imperv ious film on the contact surface .
soda
Pounds per square inch absolute (14 .7 psia 1 atmosphere at sea level ; 0 psia =
a complete absence of pressure or a vacuum) .
ns1C
Pounds per square inch gauge ( 0 psig = 1 atmosphere at sea level) .
Pyrophorie
Any fuel or other material which will ignite spontaneously upon contact with air .
Pyrotechnic
A mixture of an oxidizing agent and solid fuel designed to preduee light, heat or
perform some other non-propulsive function . Usually used as igniters .
Solid Propellant
A solid mixture consisting of a fuel and oxidizer cured in the form of a block or
"grain" which fits into the combustion chamber of the rocket for the production
of thrust .
Specific Gravity
The-ratio of the weight of any volume of a substance to the weight of an equal

volume of some substance taken as a standard or unit . Water is usually the
standard for solids and liquids , and air for gases .
7- 3

BNAU8758654
H DMSp01659579
MECHANIC'S HANDBOOK
•
Stability
State of balance . A condition in which opposing forces exactly balance or equal
each other . In rocket usage , thermal and shock stability are important . Thermal
stability refers to a material ' s ability to remain stable when a change of tem-
perature occurs, and shock stability refers to a material ' s ability to remain
stable when subjected to shock .
Storable
Refers to liquid propellant s which may be stored over a period of time at or near
ambient conditions without chemical or physical change ( e .g., NTO, N49I , IAPNA,
etc .) .
Threshold Limit Value (TLV )
Concentrations of airborne contaminants to which most workers can be exposed dur-

ing working hours ( that is , 8 hours a day, 5 days a week ) for indefinite periods
without adversely affecting their health ; sometimes referred to as MAC ( maximum
allowable concentration) .
Toxi c
Poisonous , or causing poisoning .
Ullame
Unfilled space above the liquid in a container .
Snecific Gr vity-Vapor
Is the relative density of a vapor as compared with the density of air which is
taken as 1 . Example : Acetone vapor density is 2 .00, air density is 1 .00 . •
Acetone vapors are twice as heavy as air .
Vapor Pressur e
The pressure exerted by the evaporation of a liquid at any given temperature,
7-I
c
CDNEIDENTLAL LEVEL I - UNDER PROTECTIVE ORDER ,

BNA0875865 5
H DMSp01659580
0 0
0
Boiling Freezing Specific Gravity- liquid Density Flas h

Name Formula Point , Point , Vapo P oin t
F F at STPla) lbs/cu ft lbs/gal F
Oxygen (LOX) 02 -297 -362 1 .1 71 .27 9 .527 @ -297°F Non e
Nitrogen N2 -320 -346 0 .966 50 .46 6 .746 0 -320°F Non e
Helium He -452 -456 0 .13 7 .798 1 .042 0 -452°F Non e
Fluorine F2 -306 -363 1 .3 93 .8 12 .54 @ -306°F Non e
Flex (30%/70%) F2 + 02 -301 -363 1 .2 78 .03 10 .431 Non e
Hydrogen H2 -423 -434 0 .069 4 .418 0 .591 @ -423°F N .D.(b )
Nitrogen Tetroxide (NT0) '204 70 12 3 .2 90 .34 12 .08 @ 70°F Non e
Hydrogen Peroxide ( 98,4) '202 302 31 l .L 90 .055 12 .041 @ 68°F Non e
Inhibited Red homing

Nitric Acid (I'FNA) 1610 3 150 -55 3 .2 94 .456 12 .627 @ 60°F Non e
Chlorine Pentafluoride ( CPF) CIF 5 8 -153 4 .5 129 .4 15 .9 @ 8°F None
Chlorine Trifluoride (CTF) CIF3 53 -105 3 .2 114 .0 15 .24 ® 53°F Non e
Hydrazine (HZ) 82114 236 35 1 .1 62 .691 8 .417 0 68°F 100-12 6
Monomethylhydrezine (MMH) CH3N}H1N2 189 -62 1 .59 54 .86 7 .334 @ 68°F 61-63
Unsymmetrical - pp NN( C 146 -71 2 .1 48 .8 6 .524 @ 68°F

dimethylhydrazine H2 3
(UDMH) 3 )1
Hydyne Amine Mixture 148 - 120 Heavier than Air 53 .21 7 .113 10 68°F 46
Hy drocarbo n 350-
Jet Fuels, RP-I , JP-5 -40 heavier than Air 50 .568 6 .76 @ 68°F 110
Mi xtures 525
a Standard Temperature ( 68 F) and Pressure (14 .7 p aia) .

b Not determined .
Figure 7 .1 Liquid Propellant, Pressurant , and Solvent Data (Sheet 1 of 4)

v
m Boiling Freezing Specific Gravity- Liquid Density Flash
Nam e Formul a Point , Point, Vapor, Poin t
F F at STPIa) . lbs/cu i t lbs/gal . F
Ethyl Alcohol (ALC) CH3CH20H 173 -174 49 .285 6,588 Ca 68°F 55
Pentaboranc (PB) B5H9 14 0 -52 39-14 5 .232 @ 77'F (c)
Triethylaluminum (TEA) Al (C2H5)3 381 -63 52 .3 6.99 1 (c)

Triethylboron (TED ) B(c2H5)3 20 3 -L35 43 .458 580 9 (c )
Triethyl alum inuaboron
(TAB - 859 TEB, 154 TEA ) AIB(C2H5)3 20 2 -14 1 Flame in Air 44 .784 5 , 998 7 (c )
Aceton e CH3000113 134 -99 2 .0 49 .769 6 .653 B 68'F 0
Trichloroethyleoe ( TRICH ) C11C1CC12 18 6 -124 4 .5 3 90 .873 12,148 @ 68'F N .D . (b )
Trichloromonofluoromethane
cc13 F 75 -168 heavier than Air 92 .902 12 .42 @ 6s°F Non e
(Freon MF)
Trichlorotrifluoroethane
(Freon TF) CCI2FCCIF2 118 -3 1 Heavier than Ai r 98 .43 7 13 .16 @ 68'F Non e
Tetrachlorodifluoroethane
(Freon BF) CCI2FCC12F 19 9 10 4 Heavier than Air 102 .02 7 13 .64 @ 68°F Non e
a Standard Tenperature (68 F) and Presaur e (14 .7 P sia) .

b Not determined .
c Pyrophoric
Figure 7 .1 Liquid Propellant, Pressurant, and Solvent Data ( Sheet 2 of 4 )
• •
• i •
Appearanc e
Flammable Limits ,
Name Percent by Volume Liquid Vapor Odor Vapor Hazar d
Oxygen (LOX) Nonflammable Blue Invisible None Supports Combustio n
Nitrogen N2 Nonflammable Colorless Invisible None Suffocatio n
Helium (Ile) Nonflammable Colorless Invisible None Suffocatio n
Fluorine (F2) Nonflammable Yellow Brownish Pungent Supports Combustion, Toxi c
FLOX ( 30 70%) Nonflammable Greenish Green-Brown Pungent Supports Combustion, Toxi c
Hydrogen ( H2) 4 - 75 Colorless Invisible None Fire, Suffocation
Nitrogen Tetroxide (NTO) Nonflammable Brown Brown Pungent Supports Combustion, Toxi c
Hydrogen Peroxide ! 98l)(H2O2 ) Nonflammable Colorless Invisible None Supports Combustion, Toxi c
Inhibited Ned Fuming

Nonflammable Orange Brown Pungent Supports Combustion, Toxi c
Nitric Acid ( IlIFNA)
Chlorine Pentafluoride (CPF) Nonflammable Greenish Nearly Colorless Pungent Supports Combustion, Toxi c
Chlorine Trifluoride (CTF) Nonflammable Greenish Nearly Colorless Pungent Supports Combustion, Toxi c
Hydrazine ( HZ) 4 .7 - 100 Colorless Invisible Ammonia Fire, Toxi c
Monomethylhydrazine (AAOi) 2 .5 - 98 Colorless Invisible Ammonia Fire, Toxi c
Unsymmetrical -
2 .3 - 80 Colorless Invisible Ammonia Fire, Toxi c
dimethylhydrazine (UBDBI)
Hydyne 3 .0 - 45 Colorless Invisible Ammonia Fire, Toxi c
Figure 7 .1 Liquid Propellant , Pressurant , and Solvent Data ( Sheet 3 of 4)

Appearanc e
Flammabl e Lim its ,
Name Percent by Volume Liquid Vapor Odor Vapor Hazard
Jet Fuels, RP-1, JP-5 0 .8 - 6 Colorless Invisible Kerosene Fire, Toxi c
Ethyl Alcohol (ALC) 4 .3 - 19 Colorless Invisible Alcohol Fire, Toxi c
Pentaborane ( PS) Pyrophoric Colorless Invisible pungent Pyropfioric, Toxi c
Triethy laluminum (TEA)) Pyrophoric Colorless Combustion

Invisible tyro phoric , Toxi c
byproducts
Triethylboron (TEB ) Pyrophoric Combustion

Colorless Invisible Pyrophoric, Toxi c
byproduct s
Triethylaluminumbaro n Combustion
Pyrophoric Colorless Invisible Pyrophoric
ro horic,, Toxi c
- 85% rEB , 15% TEQ byproducts y P
Acetone 3 .0 - 11 . 0 Colorless Invisible Mint-like Fire, Toxi c
Trichloroethylene (TRICH) 14 .5 - 90 Colorless Invisible Chloroform Fire, Toxi c
onofluoromethan e
Nonflammable Colorless Invisible Irritating Toxi c
(Fr
ricoaorom
MF)
Tr i triflueroethane
(FreonoTF ) Nonflammable Colorless Invisible Irritating Toxi c
odifluoroethnn e
Nonflammable Color] . .. Invisible Irritating Toxi c
,(Freon IF)r
etrachio
Figure 7 . 1 Liquid Propellant , Pressurant , and Solvent Data (Sheet 4 of 4 )
is
•
0
LIQUID PAAPELLANIS ,
PRESSURANTS AND SOLVENT S
•
CRYOGENIC S
Serv ice Metals Nonmetals Lubricant s
Liquid Oxygen Stainless Steel Teflon *

18-8 K.1- F
Copper Asbestos
Bronze Certain Silicon
Brass rubber s
Aluminum
Mone l
Liquid Nitrogen & Some Chrome- Teflo n

Liquid Helium Nickel Steels Kel-F
(Austenitic-9 per- Cotton-fre e
cent Nickel) Asbesto s
Stainless Steel Graphite (Selecte d
18-8 types )
Coppe r
Bras s
Bronz e
Copper-Silico n
alloys
Mane l
Aluminum
Shredded Lea d
Fluorine Monet None None

and Aluminum
FLOX Stainless Stee l
•
304L
34 7
Coppe r
Bras s
Liquid Hydrogen Stainless Steel Dacron *

300 series Teflon
Austenitic Kel-F
Copper Nylon
Bronze l jylar film s
Brass Asbestos impregnated
Menel with teflo n
Aluminum
*For the proper lubricants to be used in this system check the appropriate process
specification and/or specification drawing .
**9 percent nickel limited to -320e F (LN2 )
Figure 7 .2 Compatible Materials ( Sheet 1 of 4 )
7-9

BNA08758660
H DMSp01659585
MECHINIC IS HANDBOOK
STORABLE OXIDIZERS
is
Service Metals Nonmetals Lubricants
Nitrogen Tetroxide Carbon Steels Ceramic (acid *

Aluminum resistant)
Stainless Steel Pyrex glas s
Nickel Teflon
Inconel K.1-F
Asbestos (cotton free
Hydrogen Peroxide Aluminum Teflon

1060, K .1-F
1260 ,
1360 ,
5254 ,
5652
Stainless Stee l
3A ,
304ELC ,
309 ,
310 ,
316 ,
31GELc ,
317 ,
321 ,
34 7
Inhibited Red Aluminum Kel- F

Fuming Nitric Acid 1060, Teflon
EC, Polyethylen e
1100 , •
3003 ,
3004 ,
6061 ,
505-21 ,
5154
Stainless Stee l
347 ,
19-9DL ,
19-9DX ,
304ELC ,
321 ,
303 ,
316
Chlorine Stainless Steel None
Trifluoride 18-8 Pyrex glas s
Copper
Silver-solde r
Bra s
Steel
Magnesium
Aluminu m
Morel
Nicke l
*For the proper lubricants to be used in this system check the appropriate
process specification and/or specification drawing .
Figure 7 .2 Compatible Materials (Sheet 2 of 4 ) •
i-1 0
CONPTDENTTAT, LEVEE, T- UNDER PROTPCTWE ORDER ,

BNA0875866 1
H DMSp01659586
LIQUID PROPELLANTS,
PR.ESSURANTS AND SOLVENTS
STORABLE FUELS
Service Metals Nonmetals Lubricant s
Hydrazine Aluminum Polyethylen e

1100 & 3003 Teflo n
Stainless Steel ltel- F
303, unplasticize d
304 ,
321 ,
34 7
Nicke l
Monomethylhydrazine Stainless Steel Polyethylen e

304, Teflon
307 ltel- F
Aluminum unplasticize d
3003 ,
5052 ,
5154 ,
1060 ,
606 1
Durime,t 20
Unsymmetrical Low carbon Teflon

Dimethylbydrazine steels Kel-F
Aluminum Butyl Rubber
Stainless Steel JM-7 6
300 series
• llydyne Stainless Steels Teflon n
Nickel Polyethylene
Monc l
Aluminum 1100 ,
5052-0
RP-1 Most Metals Neoprene

Teflon
Kel-F
Buna-N Synthetic s
Ethyl Alcohol Most Metals Polyvinyl chlorid e

Neopren e
Rubber
Ke1-F
Teflon
Polyethylene
Asbestos gaske t
materia l
Figure 7 . 2 Compatible Materials ( Sheet 3 . of 4 )

BNA08758662
H DMSp01659587
MECHANIC ' S HANDH00K
PYROPHORIC FUELS •
Pentaborane Aluminum Kel-F *

5052-S , Kel-F-5500
6061-T6, Teflon
7075-Ti, Pluorosilicon e
2024-T3 , rubbers
3003-H14, Fluoroflex "T "
'356-T6 Glass
Stainless Steel 18-8 Viton "A" & "B "
Lov carbon steel Dry Asbestos
K-monel Garlock 23 0
Monel M-8330-B Carbon
Nicke l
Nichrome "V "
Magnesium
Fed QQ-M44A ,
Fed QQ-M-56-A263
Titanium
C-130AM ,
C-110AM
Copper
Bras s
Hastelloy
Triethvlalumiaum Stainless Steel Glass 0

Triethylberon Copper Teflo n
Triethylalumin m- Iron Kel- F
boron
•
SOLVENTS
Acetone Stainless Steel 300 Teflo n

Freons series Kel-F
Trichloroethyl - Nickel polyethylen e
cue Steel
Figure 7 .2 Compatible Materials (Sheet 4 of 4)
•
7-12

BNA08758663
H DMSp01659588
• 0
•
SAFETY CLOTIIING DAT A
Propellants and Respiratory

Solvent s Body Hood Foot Equipment
Head Face
Shield or Hood Gloves Shoes or Boots Required
Hat or Hood Clothes or Suit
Cryogenics
Non e
LOX Hard Ha t Face Shield (a ) Work Clothes Asbesto s Work
Hard Hat Face Shield )) Work Clothes Asbestos Work Yes b
LN2
Hard Fiat Face Shield a} Work Clothes Asbestos Work Yes b
Life
Neoprene Yes d
LF2 Gra-Lite Ileod(e ) Gra-Lite I1oedSe) Gra-Lite Suit(c) Neoprene
Gra-Lite lloggdlle Ora-Lite Suit(c) Neoprene Neoprene Yea d
FLOX Gra-Lite Hood(c)
Work Clothes e) Asbestos Work Yes b
LH2 Hard Hat Face Shield la)
Storable Oxidizers
Gra-Lite Hood Gra-Lit . Ho d Gra-Lite Suit Vinyl-Coated Neoprene Yes Id )
NTO
H202 Hard Hat Face Shield a) Vinyl Apron Vinyl-Coated Neoprene Yes f
IRFNA Gra-Lit. Hood Gra-Lite Hood Gr-Lite Suit Vinyl-Coated Neoprene Yea d
CTF Gra-Lite Hood ( e ) Gra-Lit e Ileod(e) Gra-Lite Suite) Neoprene Neoprene Yes d
Storable Fuel .
Gra-Lite Hood Gra-Lite Suit Vinyl-Coated Neoprene Yes d )

HZ Gra-Lite Hood
1551 Gr.-Lite Hood G,.-Lite Hood Gra-Lite Suit Vinyl-Coated Neoprene Yes d)
UDMR Gra-Lite Hood Gra-Lite Hood Gra-Cite Suit Vinyl-Coated Neoprene Yes d
IIYDYNE Gra-Lite Hood Gra-Lite Boyd Gra-Li to Suit Vinyl-Canted Neoprene Yes d
RP-1 Hard Het Face Shieldla) Work Clothes Neoprene Work Yes d
Herd Hat Face Shieldla) Work Clothes Vinyl-Coated Work Yes d
Ethyl Al .
(a Safety glaesea oust be used when face protectors are used .

h Required when suffocation hazard is present .
(, Armaion suits will replace Gra-lite suits as they become available .
SS
d Required when MAC value is exceeded .
S Aluminized hood coveralls and gloves required for full protection .
Sf Required when essive
se vapors are present .
Figure 7 .3 Safety Clothing Data (Sheet I of 2)

SAFETY CLOTHING DATA
Propellants and Respiratory

Solvents Head Face Body Hand Foot Equipment
Hat or Hood Shield or Hood Clothes or Suit Gloves Shoes or Boots Required
Pyroohoric Fuel s
PB Gra-Lite Hood Gra-Lite Ho ggd Gra-Li a Suit Vinyl Coated Neoprene Yes (d)
TEA Hard Hat Face Shield(a) Apron g) Asbestos Heavy Rubber Yes d 1{
T ED Nerd Hat Face Shield lj 2 Apron g Asbestos Heavy Rubber Yea d/
TEAB Bard Hat Face Shieldla / Apron g! Asbestos Heavy Rubber Yes d )
Solvents
Acetone Hard Hat Face Shield(a) Plastic Apron Neoprene Work Yes (d)
Freons Hard Hat Face Shield a2 Plastic Apron Neoprene Work Yes Sd
Trich Hard Het Face Shield a / Plastic Apron Neoprene Work Yes ld ~
(a) Safety glasses must be used when face protectors are used .
((d Required when DISC value is exceeded .
g Impregnated asbestos open-back jacket or apron .
Figure 7 .3 Safety Clothing Data (Sheet 2 of 2 )
•
• •
LIQUID PROPELLANT'S,
PRESSURANPS AND SOLVENT S
FIRST AID TREATMENT
ALL MATERIAL S
CRYOGENS , STORABLE OXIDIZERS , STORABLE FUELS, PYROPRORIC FUELS , AND SOLVENTS
SKIN CONTACT :
Flusb with large quantities of water for purposes of dilution, warming the affected
area in the case of cryogens , cooling the affected acne in the case of pyrophoric
fuels , and generally washing the area off to remove the material .
EYE CONTACT :
Hold the eyes open and flush with water to wash the liquid out for a minimum period
of 15 minutes .
INHALATION :
Remove the person from the contaminated area . Do not allow the person to walk ; carry
him .
INGISTION :
Summon medical help .
BREITHINO STOPS :
Apply artificial respiration or mouth-to-mouth resuscitation .
In all cases when a person requires First Aid--summon medical help .
FIRE CONTROL METHOD

Propellant,
and Hater Cooling and Dilution Suffocation Metho d
Solvents
Dry
Stream Spray Fog CO2 Chemical Foam
Cryogenics
LOX Na No Yes No No No
152 Nat Flammabl e
Ae Not Flammabl e
LF2 No No Possibly(a) No No No
FLOX No I No Possibly(a) No No No
LH2 Yes Yes Yes Yes(b) Yes No
(a) Fluorine FLOE and CTF react with water ; therefore , it cannot be used to put out
a fluorine- fed fire, but a controlled fog stream c an supstantially reduce toxic
effluent by controlled reaction .
(b) CO2 is not as effective as water because of the high temperatures involved .
Figure 7 . 4 Fire Control Methods ( Sheet 1 of 2 )
• 7-15
CDNFfDF.nTTAl, l,FXF.l, T- ITNDF.TO PROTF.CTWF ORI)RR ,

BNA08758666
H DMSp01659591
MEcmNlC's HANDBOOK
FIRE CONTROL METHO D

Propellants
and Water Cooling and Dilutio n Suffocation Method
Solvents Dry
Stream Spray Fog CC2 Chemical Foam
Storable Oxidizer s
NTO I Yes l~ I Yes I No ( No No

H2O2 Ys C Yes 0 Yes No No No
IRENA Yes1d~
Yes Yes d Yes No No No
CTF No No Possibly ( a) No No(e) N o
Storable Foe s
HZ Yes Yes Yes Yes Yes yes(f)

Mtn Yes Yes Yes Yes Yea YesSI
UDPDi Yes Yes Yes Yes Yes Yes f))
HYDYNE Yes Yes Yes Yes Yes Yes 1)
RP-1 No No Yes Yes Yes Yes
Ethyl Al e Yes Yes Yes Yes Yes No (Dissolves )
lyrophoric Fuel s
PB No No Possibly(g) Yes h( Yes h) Yes

TEA No No Possibly g) Yes h Yes h) Yes 1}
TEB No No Possibly()g }( Yes h Yes h(} Ye
TEAR o No No Possibly g) Yes(h) Yes h/ Yes sN s )
Solvent s
Acetone No I No Yes Yes Yes Yes

Preons Not Flasmable(j )
TRICH No I No Yes Yes Yes Ye s
(a) Fluorine PLOX aad COP react with water ; therefore, it cannot be used to put out a
fluorioe -fed fire , but a controlled fog stream can substantially reduce toxic ef-
fluent by controlled reaction .
`c) Large amounts of water can effectively dilute peroxide .
{d) Large amounts of water on IRPNA can cause an increase in vapor preasure in an
enclosed area .
e) Dry chemicals can be used to decontaminate spills .
C) Foam tends to break down rapidly due to the high temperature of bydrasine-fed
fires . C02 is effective in most cases involving small fires especially for pro-
tection of personnel .
(g) Pyrophoric fuels react violently with water , therefore , water cannot be used to
put out a fire , but a controlled fog can be sand to burn up the fuel faster while'
providing cooling for the surrounding area .
(h) CO2 . dry chemical , and foam are effective as long as they cover the fire, once
removed, the fire may reignite .
i Foam and water deluge are the most effective control .
j At the present time , Freon solvents are considered to be nonflammable .
Figure 7 .1k Fire Control Methods ( Sheet 2 of 2 )
7-1 0
CONEIDENTLYL LEVEL I- UNDER PROTECTIVE ORDER ,

BNA0875866 7
California, Po. C`' 97-1554
H DMSp01659592
SECTION 8
RIGGING
CONTOYfS
Page
Introduction . 8-1
Estimation of Safe Loads . 8-1
Estimating Load Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Lstimating Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Plow Steel Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Inspection of Wire Rope . . . . . . . . . . . . . . . . . . . . . 8-6
Co mmon Causes of Wire Rope Failures . . . . . . . . . . . . . . . . . . . 8-6
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Manila hope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Knot Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Hoisting Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 2
Chain Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Wire Rope Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14
•
Sling Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-15
Hitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 5
Lifting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Wire Rope Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Lye Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Shackles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Cable Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 9
Pull Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Additional Rigging liquipment . . . . . . . . . . . . . . . . . . . . . . . . . 8_23
Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Skids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Hoisting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Fork Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Block and Tackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Inclined Planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

BNAU8758668
H DMSp01659593
RIGGING
RIGGING
INTRODUCTION
Rigging consists of the ropes, cables, chains , slings, pulleys, winches, and related
materials used in moving heavy equipment . Safe rigging operations require observance
of correct procedures and knowledge of the materials used . hoisting equipment is
made according to rigid standards of manufacture . It is tested and its limits veri-
fied by such national societies as American Society for Testing Materials (ASTM) .
Thus the user i ared that an individual item is suitable for use within certain
load limits . These limits are indicated in various tables in this section . Great
personal harm and extensive property damage can result from failure to observe the
design limitations of hoisting equipment or from failure to recognize evidence of
wear , weakening, or damage .
ESTLMATION OF SAFE LOADS
It is often necessary to make quick estimations of the load capacity of equipment

used in rigging operations . The Figure 8 .1 presents methods for quickly determining
the safe load capacity of commonly used rigging .
Safe Load in Ton s

Rigging Equipment is Equal To : Remark s
Eye Bolts 202 D = diameter ( in inches) of

• bolt stock where it forms
the eye .
Not accurate whea D i s
greater than 1 inch .
Manila Rope g2 D = diameter ( in inches) of

Sisal Rope 0 .7 DZ rope .
Not accurate when D i s
greater than 1 inch .
Plow Steel 802 D = diameter ( in inches) o f

Wire Rope wire rope .
Open Eye Hooks 02 D = diameter (in inches) a t

the point where the inside
curve starts its arc .
(See Figure page 8-9 . )
Shackles 602 D = diameter (in inches) o f

the shackle . Do not use pin
diameter . ( See figure pag e
8-18 . )
Chain 602 D - diameter ( is inches) o f

chain stock .
Figure 8 .1 Estimatioa of Safe Load s

•
8- 1

BNAU8758669
H DMSp01659594
MECHANIC'S HANDBOOK
•
ESTIMATING LOAD WEIGHTS
Frequently , the rigger has to compute loads in order to make the best use of his
equipment and assure safety of personnel and protection of equipment . Both the load
limit of the equipment being used and the approximate weight of the material being
bandied must be known .
Determine the size of the object by visualizing it as being square or rectangular .

Deduct any small component parts or offshoots from the object to be lifted -, and cal-
culate the volume of the object in cubic inches or feet by multiplying the object's
length times its width times its height . Take the component parts or offshoots and
do the same thing . Add both answers together to find total volume of object to be
lifted .
Determine what the object is made of and its weight in pounds per cubic inch or foot
(see Figure 8 .2), Multiply the weight per cubic foot or inch times the object's
volume . This will give the approximate weight of the object . As an extra margin of
safety , overestimate the object ' s weight a little .
Weights of Materials (Solids )
Pounds Per Pounds Pe r

Material Cubic Inch Cubic Foot
Wood ( Spruce ) ,016 27

Water .036 62 . 5
Earth .058 10 0
•
Sand .070 12 0
Concrete .083 14 4
Cast Iron ,24 442
Steel .28 48 8
Brass .31 53 4
Lead ,44 710
Aluminum . 092 160
Copper .322 555
Figure 8 . 2 Weights of Material s
Steel plate weighs approximately 10 pounds per square foot for each 1/4-inch of thick-
ness . Alomimum weighs approximately 1/3 as much as steel . The relationship of the
weight of steel to the weight of other materials can be see in the table above .
8-2

BNA0875867 0
H DMSp01659595
RIGGING
•
ESTIMATING COMIR OF GRAVITY
The rigger has to determine the approximate locations of the center of gravity of a
load he intends to lift . The center of gravity is the point where the entire weight
of the object is theoretically concentrated . This point , when the object is freel y
suspended from a hook , will always hang directly below the hook . Finding the exact
center of gravity requires mathematical calculations , but for the average rigging job
it can be estimated closely enough . Figure 8 .3 below shows some familiar and some
irregular-shaped plane figures representing , say, the length or cross section of the
object and showing the approximate locations of their centers of gravity Most
centers of gravity are within the ob j ect, but some are located outside .
X
x
D
Figure 8 .3 Approximating the Location of the Center of Gravity of Plane Figures
•
A simple bnt near-exact method of locating the center of gravity of a plane figure
of irregular shape is to cut out a similar figure, at any convenient scale, from a
piece of cardboard (see Figure 8 .4) . Punch pinholes near two adjacent corners of the
cardboard and suspend it freely from one pinhole by a pin or nail stuck into a wall .
Suspend from the nail or pin a small weight attached to a string, and draw a line on
the card along the string . Remove the cutout and place the nail in the other hole
and draw another line . Where the two pencil lines cross is the center of gravity .
STEP I . STEP 2 . STEP 3.
• Figure 8 .4 Locating Center of Gravity
9-3

BNAU8758671
H DMSp01659596
PLOW STEEL WIIOE ROPE
Plow steel rope is more flexible than standard wire rope and is made of wire drawn
from specially selected high strength steel to produce a finished rope of great
strength and toughness capable of resisting severe abrasion . Plow steel rope is
recommended for all types of hoisting ( see Figure 8 .6) and for all rough uses requir-
ing maximum strength and toughness . See figure 8 .5 for safe loads .
Small loops often develop in the slack portion of wire rape during handling ( Figure
8 .7) . If tension is applied to the rope when loops exist in it, sharp kinks (Figure
8 .8) will form resulting in "unlaying " of the rope (Figure 8 . 9)• It is impossible to
remove a kink which has been formed in a rope , and serious weakening occurs at the
kinked point. Further damage can be inflicted upon a wire rope by rust or abrasion .
No wire rope which has been subjected to weakening by kinking , rust, or abrasion
should be used where the possibility of damage to personnel or material exists .
Diameter Safe Load Diameter Safe Loa d

in Inches in Pounds in Inches in Pound s
1/4 1,100 1 16,000

5/16 1,800 1-1/8 21,200
3/8 2,400 1-1/4 26,000
7/16 3,300 1-3/8 31,400
1/2 4,200 1-1/2 37,000
9/16 5,400 1-5/8 43,200
5/8 6,600 1-3/4 49,600
3/4 9,400 1-7/8 56 .800
7/8 12,800 2 64,400
•
Figure 8.5 Safe Load in Founds for Plow Steel Hoisting Rope
(Six Strands of Nineteen Wires , Hemp Center )
NOTE : Slings may be covered only with clear protective coating through which any
defects can be readily seen .
8-4

BNAO8758672
H DMSpO1659597
RIGGING
• THIS IS A 6 a 7 ROPE
(6 STRANDS OF 7 WIRES EACH)
Figure 8 .6 Plow Steel Wire Rope
INV
Figure 8 . 8 Sharp Kink
Figure 8 .7 Small Loop Figure 8 .9 Unlaying

0
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MECAANIC~S AACDBOOK
•
INSPECTION OF WIRE RAP E
Frequency : Wire rope should be inspected before each use . Frayed , kinked , worn, or
corroded rope should be replaced .
Procedure : The weak points in the rope , or the points where the greatest stress
occurs , should be inspected with extreme care .
1 . Worn spots will show up as shiny flattened spots on the wires . Measure some of
these shiny spots . If the eater wires have been reduced in diameter by one-
fourth, the worn spot is unsafe .
2 . Broken wires : When 4 percent of the total number of wires is the rope are found
to have breaks within the length of one rope lay , the rope is unsafe .
COMMON CAUSES OF WISE RAPE FAILURES
1 . Allowed to drag over obsteble s
2 . Overwinding or cresswinding on drum s
3 . Subjected to moisture, acid fumes, and salty air
4 . Improperly attached fitting s
5 . Permitted to untwis t
6 . Subjected to excessive heat
7 . Kinks •
5. Subjected to severe overload c
9 . Destroyed by interaal wear caused by grit penetrating between strands
10 . Used without proper cable clam p
11 . Scuffed and damaged when the rope slides as the lift or turn is made
12 . Crushed when the load is lowered upon them
13• Damaged by putting sails or other sharp objects through the strands
14 . Kinked by tieing two together to make a longer rope
15 . Kinked by not removing small loops formed in a slack rope before applying
tensio n
B-6
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RIGGING
•
CHAINS
The safe load limits of chain can be obtained from Figure 8 .10 and Figure 8 .12 .
These tables suppose a new or like- new condition and that the chain has not been
overstressed . A chain may also be damaged by abrasion and rust . Careful inspection
of a chain should be made periodically regardless of the frequency of its use . If it
is stretched , worn or rusted , it should not be used . Stretching can be detected by
small checks or cracks in the links , by links binding on each other , and by elongation
(Figure 8 .11 ) . Useful chain life can be extended by prevention of overloads , protec-
tion from rust and by protecting the chain from sharp corners or abrasive applica-
tions .
Diameter of Link Stock, Safe Load Diameter of Link Stock , Safe Load
Inch Pound Inch Poun d
1/4 1,000 5/8 6,600

3/8 _ 2,300 3/4 9,500
1/2 4,200
Figure 8 .10 Table of Safe loads for Standard Carbon Steel Chai n
Chain Terminology :
Si- of chain . . . . . . . . . . . The diameter of chain link stock
• Pitch . . . . . . . . . . . . . . . The distance from the center of one link to the

center of the next
Proof test . . . . . . . . . . . . Two load, expressed in pounds, that a chain will
carry, (two times safe working load) without
deformatio n
Breaking strain . . . . . . . . . . The load point at which a chain will break . It
is approximated as five times the safe working
load .
Safe working lead . . . . . . . . . One-half of proof test
NORMAL
20%-
WORN
STRETCHED AFTER
BEING OVERLOADE D
• Figure 8 .11 Detecting Chain Stretching
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MACHINIST ' S HANDBOOK
Choker Has et
Hitch Hitc h
Size , Vertical
loads are Given for Each Leg
Vertical Vertical
Inch Load 60e Angle 455 Angle 30° Angle Load Load
3/8 3,182 2,757 2,251 1,592 2,387 5,73 0

1/2 5,733 4,965 4,045 2,867 4,300 1D,320
5/8 8,433 7,303 5,963 4,216 6,325 11,580
3/4 11,000 9,526 7,778 5 .500 8 .250 19,800

7/8 14,700 12,774 10,430 7,375 11,062 26,55 0
1 19,166 16,950 13,552 9,583 14,375 34,50 0

1-1/8 25,166 21,795 17 .795 12,583 18,875 45,30 0
1-1/4 32,500 28,146 22,981 16,250 24,375 5D,850
Figure 8 .12 Safe Loads in Pounds for Alloy Steel Chains
FIGURE 8 .13 Chain Angles
MANILA ROPE
Manila rope requires caution in its use because of the difficulty encountered in
determining its condition and because of its lower resistance to weathering than
other hoisting materials . It is subject to abrasion and must be protected from rough
surfaces and sharp corners . Moisture affects rope adversely and special care must be
obse rv ed in handling and storage . It should not be stored wet, and , even when dry ,
it should be stored in loose coils with provision for free circulation of dry air .
Damage by aging or moisture may be detected by twisting a rope against the lay to
uncover the center of the rope . A dry powdery condition indicates deterioration . A
rope in this condition should not be used . Rope should also be examined for frayed
strands or fibers or variations in color , which indicate that sections have been
subjected to unequal weathering . Examination of used or aged rope against new rope
will reveal its condition . Safe loads for the most commonly used manila rope sizes
are listed in Figure 8 .14 .
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RIGGIN G
• Diameter Circumference , Feet per Weight 100 it Breaking Strength , Working Load ,
Inch Inch Pound Pound Pound Pound
3/16 5/8 66 .60 1 .5 450 90

1/4 3/4 50 .00 2 .0 600 120
5/16 1 34 .50 2 .9 1,000 200
3/8 1-1/8 24 .40 4 .1 1,350 270
7/16 1-1/4 19 .00 5 .3 1,750 350
1/2 1-1/2 13 .30 7 .5 2,650 530
9/16 1-3/4 9 .61 10 .4 3,450 690
5/8 2 7 .50 13 .2 4,400 880
3/4 2-1/4 6 .00 16 .7 5,400 1080
13/16 2-1/2 5 .13 19 .5 6,500 130 0
7/8 2-3/4 4 .45 22 .5 7 .700 154 0
1 3 3 .71 27 .0 9,000 1800
1-1/16 3-1/4 3 .20 31 .3 10,500 210 0
1-1/8 3-1/2 2 .78 36 .0 12,000 240 0
1-1/4 3-3/4 2 .40 41 .8 13,500 270 0
1-5/16 4 2 .09 48 .0 15,000 300 0
1-1/2 4-1/2 1 .67 60 .0 18,500 370 0
1-5/8 5 1 .34 74 .4 22,500 450 0
1-3/4 5-1/2 1 .12 89 .5 26,500 530 0
2 6 .93 108 .0 31,000 620 0
Figure 8 .14 Manila Hope Data

(Based on US Spec . T-R-601 )
IINOT STRENGTH
•
A manila rope will separate first at a point where it is subjected to unnatural
stress , sharp corners and turns being common points of separation . Figure 8 .15 illus-
trates various knots and their effect upon the strength of lines follows . It should
be used in conjunction with the Manila Rope Data, Figure 8 .14 .
(A knot will reduce rope strength to

the indicated percentage of its
original value . )
Clore Hitch Bowline ( outside) Bowline (inside )
scv
(75%)
• Figure 8 .15 Knot Strength of Manila Rope ( Sheet 1 of 2)
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Timber hitch and half hitch •
Long splic e
(68% )
Figure 8 .15 Knot Strength of Manila Rope ( Sheet 2 of 2 )
HOISTING HOOKS •
There are two types of hoisting hooks co mmonly used at the Field Laborato ry on hoist-
ing equipment . These are the slip hook with a safety latch , and the grab hook (see
page 8 .11) .
The slip hook , with a safety latch , is the most commonly used hook . Slip hooks with
their large throat opening permits easy installation of such lifting equipment as
slings, shackles , etc . The safety latch is not designed to hold rigging equipment
in the hook under load conditions but only when under slack or no-load conditions .
While hitching to a part, the slings, shackles , etc ., will stay on the hook with the
safety latch in the closed position . A wide sling angle will cause the sling to
slide up the point of the hook, distorting the safety latch and allowing the sling to
slip off the hook . Slip -hooks are also used on wire rope and chain slings .
The grab hook has a narrow throat opening and is generally used with alloy chain
slings . The small opening allows the hook to be positioned between the links of a
chain , making it useful for hitching the sling to any desired length and preventing
slippage .
The maximum throat opening ( spread ) of a hook should not exceed 35 percent beyond the
designed opening . See Figure 8 .18 , for the designed opening dimensions for slip
hooks .
Hooks are designed for operation within established load limits . These limits can be
computed readily by reference to either the formula or the table . on next page .
A hook is designed to fail by straightening before its chain is overloaded . Because
of this design feature , a type or weight of hook other than that originally installed
should not be used without full knowledge of the load limits of both book and chain.
is
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California, No. C`' 97-1554
H DMSp01659603
RIGGING
•
SAFETY
LATCH
SUP HOOK GRAB HOOK
Figure 8 .16 Hook Type s
become AT "C*E%CEEDS
10% REPLACE
Figure 8 .17 Hook Dimension s

•
The safe working capacity ( SWC) of a book can be approximated in tons by squaring the
diameter of the book in inches at the point where the inside curve starts its arc
(dimension A in Figure 8 .17) . Thus, when A = 1-1/4 inches, SWC = A2 or SWC - 1-1/4 z
1-1/4 = 1-9/16 tons . Safe working loads can be computed in this manner or can be
determined from Figure 8 .18 .
Dimensions, Inch
Safe Load in Pound s
A B C D
11/16 7/8 1- 1/16 4- 15/16 1,200

3/4 1 1- 1/8 5-13/32 1,400
7/8 1-1 /8 1- 1/4 6- 1/4 2,40 0
1 1-1/4 1- 3/8 6- 7/8 3,400
1- 1/8 1-3/8 1- 1/2 7- 5/8 4,200
1- 1/4 1-1/2 1-11/16 8-19/32 5,00 0
1- 3/8 1-5/8 1- 7/8 9- 1/2 6,OOo
1- 1/2 1-3/4 2- 1/16 10-11/32 8,00 0
1- 5/8 2 2- 1/4 11-27/ 32 9,400
1- 7/8 2-3/8 2- 1/2 13- 9/32 11 .00 0
2- 1/4 2-3/4 3 14-13/16 13,60 0
2- 5/8 3-1/8 3- 3/8 16- 1/2 17,00 0
3 3-1/2 4 19- 3/4 24,00 0
Figure 8 . 19 Hoisting Hook Dimensions and Safe Loads

•
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MLCHANIC'S HAKDBOOIS
SLINGS
is
There are many types of slings in use , some of which are illustrated below . The
choice of sling will depend on the materials being handled , s slings being mo
secure or less apt to damage the load than others . Slings are made of improved plaw
steel wire rope , chain , or web belts . Information as to the strength and care of
these materials can be found elsewhere in this section .
Slings most be inspected and tagged for maximum working loads every 6 months, It is
the responsibility of the user , however , to use the appropriate equipment in the
prescribed manner and make more that the equipment is in a safe condition .
BELT TYPE SLING S
NYLON STITCHED
80 PERCENT
EFFICIENT
1,000 ter
WOVEN NYLON
0 RIN G
SAFE WORKING LOAD WILL BE

STENCILED ON THE SLIN G
Figure 8 .19 Belt Type Slings
Woven nylon belt type slings are used to lift objects that are easily crushed or
damaged , such as thin-wall vessels or thrust chambers . The belt sling, being wider
than a rope or chain, spreads the force that tends to crush the object during lifting
over a larger surface area . Thus there is less concentrated pressure against the
object and less chance of c ru shing or damaging it .
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RIGGIN G
•
CRAIN SLINGS
Figure 8 .20 Chain Slings
Chain sling is not used for making heavy lifts for two reasons : ( 1) flaws are more
difficult to detect in chain than in wire rope ; and (2 ) the links in a chain big
enough to carry our larger assemblies would be difficult to snake in and around
some of the complex shapes that must be handled . Although chain slings have their
limitations , they are useful for rigging in particular applications where beat and
acids are present . One advantage of a chain which makes it very useful as a sling,
is that it may be shortened by merely positioning a now link in the grab hook throat .
Never place the point of the hook through the center of the link ( see Figure 8 .20
• for correct attachment) .
WIRE ROPE SLING S
For lifting and turning use, a wire rope must be made into a sling . This is done by
forming a loop at each end and splicing the wire rope together , a job for the
Maintenance Department . Onee the sling is put to use it is the rigger ' s responsi-
bility to keep it from becoming damaged . Most slings are damaged through careless-
ness : using too small a cable for a lift, using the wrong hitch , setting the work
on the sling , not straightening the rope before attaching it to the hook, and fre-
quently, not using a cable guard when wrapping the sling around a sharp corner .
Wire rope is used for most of our slings because of the limitations of other materials .
Wire rope is strong--much stronger than manila rope and equally as strong as chain ;
it is flexible no that it can be laid in and around a complex assembly or casting ;
it has good resistance to abrasion ; and wire damage can be readily detected .
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MECHANIC IS HANDBOO K
Safe load in pounds for new improved plow steel wire rope slings under different
loading conditions (6 strands of 19 wires, hemp center )
Safe Working Load, Weight in Pound s

Sling or Swo Sling or Two Sling or Two
Size Single Wire Wire Ropes - Wire Ropes - Wire Ropes -
Dias,eter R.P. Sling Used at 6o - Used at 45. Used at 30-
Inch Vertical Lift Degree Angle Degree Angle Degree Angle
90° G° N4.5- 30a
Load Angle Load Angle Load Angle Load Angl e
3/8 2,500 4,300 3,600 2,50 0
1/2 4,300 7,400 5,800 4,30 0
5/8 6,600 11, 400 9,400 6 .60 0 •
3/4 9,400 16, 200 13,000 9,40 0
7/8 12,800 22, 100 17,400 12,80 0
1 16,ooO 27 , 700 23,200 16,00 0
1-1/8 21,200 36,700 29,700 21,200
1-1/4 26,000 45,000 36, 200 26,000
1-3/8 31,400 54,300 - 43,500 31,40 0
1-1/2 37,000 64,000 52,200 37,00 0
Figure 8 .21 Wire Rope Sling Safe Working load s
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GIGGING
SLING STRDNGTE
•
The tension on sling depends on the load and on the angle of the sling to the 1--d-
A vertical sling is the strongest , while a widely spread sling can develop tensions
greatly in excess of the acteal load being lifted . Sling load angles of lees than 45
degrees should be avoided since they result in high sling tensions which can lead to
sling failure or. crushing of the material being lifted . The following illustrations
show the relationship of sling load angle to sling tension .
O
a~
O
9
90o 570 570
10 0 100
Figure 8 .22 Effect of Sling Angle on Sling Tension
75% FULL 1004 FULL 200% FULL

LOAD RATING LOAD RATING LOAD RATING
CHOICER HITCH SINGLE CABLE HITCH BASKET HITCH
DOUBLE CHOKER HITCH DOUBLE WRAP
2 ENDS DOWN
HOOK CABLE
Figure 8 .23 Commonly Used Hitches and Approximate Load Carrying Capacity of Hitche s
•
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MECHANIC'S HANDBOOK
LIFTING ACCESSORIES •
WIRE ROPE CLIPS
Use of Crosby clips is probably the most common method of securing a loop in wire
rope . These clips should be spaced at least six rope diameters apart, and all clips
must be placed on the rope with the U-bolts bearing upon the short or "dead" end of
the rope . A heavy-duty thimble should be provided for every eye . When properly made,
a clipped eye develops about 80 percent of the strength of the rope . Do not use
malleable iron clips or brass clips .
To install Crosby clips, first hind the rope on itself at the toe of the thimble .
Then apply the clip farthest from the thimble, at about 4 inches from the dead end
of the rope , and thoroughly tighien it . Next, put on the clip nearest the thimble
and screw the nuts on hand tight . Then put on the intermediate clips hand tight .
Apply tension to the rope , and while the rope is under tension , thoroughly tighten
the rest of the clips . ( See Figure 8 .24 and 8 . 25 for details .)
Figure 8 .24 Installation of Crosby Clip s
Diluleter o f Distanc e
Rope, Inch Number of Clips Between Clips Efficiency
1/4 to 3/8 3 --1/4 "
7/16 to 51/8 4 3 - 3!4 "

ii4 to 1-1/8 1 U - 3/4" 77% to 82%
1-1/4 to 1-1/2 6 9• '
1-5/8 to 1-3/4 7 10 - 1'2 "
Figure 8 .25 Number of Clips and Distance Between Clips for Safety
•
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RIGG ING
LYE BOLT S
•
If a casting or housing has threaded holes, eye bolts s wed into the holes can be
very useful in the making of lifts . Two precautions concerning eye bolts should be
considered : all threads of the eye bolt should be fully engaged , and slings running
between eye bolt and hook should be as close to a vertical attitude as possible . In
other words, maintain as great a load angle as possible . Manufacturers of eye bolts
guarantee the safe working load in pounds for the bolts they manufacture . By refer-
ring to the manufacturer ' s catalog the safe working load for each individual eye bolt
may be found . Recommended working loads for various points of hitching are shown in
Figures 8 .26 and 8 .27 .
PULL
Size, _
Inch
SIZE
F 4/
/
/,/
,
1/4 250 40 30
1/2 1,100 50 40
5/8 1,800 90 65
3/4 2,800 135 100
7/8 3,900 210 150
1 5,100 280 210
1-1/4 8,400 500 370
• 1-1/2 12,200 770 575
1-3/4 16,500 1 , 080 800
2 21,800 1,440 1,140
Figure 8 .26 Ordinary Drop Forged Steel Eye Bolts

Recommended Working Load, Pound
PUL L
Size,
Inch
SIZE
1/4 300 30 40
1/2 1,300 140 150
3/4 3,000 250 300
1 6,000 500 600
1-1/4 9,000 800 900
1-1/2 13,000 1,200 1,300
2 23,000 2,100 2,300
2-1/4 37, 000 3,800 4,300
Figure 8 .27 Drop Forged Steel Shoulder-Type Eye Bolts

Recommended Working Load, Poun d
•
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SHACKLES •
Shackles are very useful accessories in rigging operations, and when correctly used
can very often make what might have been a poor hitch a very efficient one . For
example, shackles can be used to hitch slings to stationary eyelets which provide
flexibility to the hitch during a turning operation . If a shackle had not been used
the sling might have been scuffed by the eyelet when a turn was performed . Shackles
may also be used to prevent point loading crane hooks by slipping a shackle over the
hook and passing the sling through the shackle .
Some Do's and Dont' s concerning shackles are listed below :
1 . They should be of the threaded -pin type . The pin should thread into the mating
part easily .
2 . Shackles are not proof loaded (except as a sling assembly ) by the Maintenance
Department and one hould calculate the approximate safe working load by using
the formula (SWL = D2 x 6) prior to selection and use of the shackle (see
Figure 8 .28) .
3 . Do not use pin diameter in calculations .
4 . Shackles should be examined carefully for worn spots , cracks, fractures, or

being sprung . Discard for any defect listed above .
5 . Do not use anything other than the designed pin in a shackle . If pin is missing,
replace pin with like type, or replace shackle .
Figure 8 .28 Shackle Safe Working Loa d
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RIGGING
•
CABLE GU4RDS
Many months of se rv ice can be added to the life of a sling or cable if a few simple
rules are followed , one of which is the protection of cables over sharp edges or
sharp bends . This can be accomplished by the use of cable guards . Cable guards are
designed to fit . over the contour of the part . One side of the guard is a near match
to the contour ; the other side is shaped to allow the cable to pass over a curving
surface , therefore protecting the cable from the sharp edge . (See Figure 8 .29 . )
RADIUS
RADIUS
Figure 8 .29 Cable Guard s
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MECHANIC'S HANDBOOK
40
PULL LIFTS
Probably the most widely used piece of hoisting equipment at the Field Laboratory
next to the sling, is the pull lift . There are many types, sizes, and capacities .
The s i'x s range anywhere from 3/4 ton to 15 ton . Each size will have the load
capacity stamped on the side of the roller housing .
Before making a lift with a pull lift, one must always verify its safe working con-
dition . Pull lifts should be thoroughly inspected .
Examine the chain to see that the links and rollers work freely, and that the chain
not bent or twisted . The chain should also be checked for elongation . Should
the pull lift ever get splashed with water or oil, it should be sent to Maintenance
for serv ice . Under no conditions should the pull lift be serviced by anyone except
Maintenance personnel .
On chains with unsecured dead ends a safety ring shall be attached to prevent running
the chain through the housing .
Inspect the top and bottom hooks for correct suspension and application of loads .
The load must be carried in the center of the hook , not on the tip because books are
only efficient when the load is carried in the center . If the load is incorrectly
applied so that it is carried out at the tip, the hook will open at approximately
one-half the rated capacity . The maximum opening of the hook, for safety sake,
should not exceed 35 percent beyond the normal opening . Make sure the hook nut is
tight and riveted or pinned .
Operating instructions : ( See Figures 8 .30 and 8 .31 .)
With Load ,
To lift a load, turn the pawl lever "A" so that the marking "UP" is visible, and the
lever seats in the handle slot . Operate the handle " B" with a pumping action .
To lower the load , turn the pawl rod lever "A" so that the marking "BN" is visible
and the lever seats in the handle slot . Operate the handle-"13" with a pumping action .
The pumping action in hoisting or lowering should be with the force applied on the
downward movement of the handle , and with the upward movement free . The opposite
action is obtained by reversing the movement of the handle .
Without a Lead :
Turn the pawl rod lever "A" to the neutral position . To raise or lower the empty
hook to the desired position, turn hand wheel "C . "
To pull the chain, hold the two lines of the chain tightly with one hand , turn the
hand wheel "C" to free the load brake, and pall the chain book towards the roller
housing . Always use the band wheel instead of the handle when operating without a
load .
Raising the lower hook to a point where it jams against the housing, or excessive
overloading of the pull lift, may "freeze" the load brake . If this occurs, the
brake can be released by setting the pawl rod lever "A" to the "DN" position, tapping
the handle with a hammer , and lowering with the handle .
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0 • •
PAWL POSITION FOR U P
PAWL POSITION FOR NEUTRA L
NOTE : ROTATE HANDLE SO THAT THE FORCE

IS ON THE HANDLE ON THE DOWNWARD
MOTION FOR EITHER LIFTING OR
LOWERING A LOAD
PAWL POSITION FOR DOW N
LOA D LOAD
N
(LIFTING A LOAD) (LOWERING A LOAD) Figure 8 .30 Pu11 Lift Operation
MIJCHANIC ' S HANDBOOK
Checking Load Brake

•
To check out the load brake to see if it is operating properly , do the following :
Put the pawl rod lever "A" in the neutral position . Bung the upper book on a con-
venient beam or eye bolt . Grasp both ends of the chain and pull the chain through
the housing . You should be able to pull the chain hook towards the housing but not
away from the housing : If the chain hook can be pulled away from the housing the
load brake is faulty . Send to maintenance for repair . Usual cause of faulty load
brakes is moisture or oil getting on the discs and causing slippage of the load brake .
Figure 8 .31 Checking Pull Lift Load Brak e
Never Use a "Cheater " on the Handl e
Manufacturer 's instructions on the operation of the pull lift state that when the
handle gets hard to pull, you havereached the maximum safe working load . The maxi-
mum safe load of a pull lift can be exceeded through normal use and without the aid
of a "cheater" . Unknown loads should be checked before the, lift is made .
•
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RIGGIN G
ADDITIONAL RIGGING EQUIPMENT

•
JACKS
When jacks are used , blocks should be placed under the load during lifting in case
the jack should fail . No part of one's body should e r be exposed to a situation
in which it would be dangerous if the equipment failed .
When a jack is used in a horizontal position , it should be lashed or supported to

prevent it from falling should the object unexpectedly move faster than the jack .
ROLLER S
For moving heavy loads across a floor or ground , hardwood rollers ( usually maple)
7-1/2 inches in diameter and 10 feet long are co mm only used . Pipe rollers may also
be used . Under no circumstances should an oxygen cylinder or any other gas cylinder
be used as a roller . Cylinders when full may be pressurized in excess of 2,000 psi,
and constitute a high pressure gas hazard if mishandled .
SKIDS
Skids are commonly used under heavy machinery or other equipment that is being moved .
The skids can be used as stationary rails or can be used as a sled .
HOISTING EQUIPMENT
Cranes, derricks, hoists, and such auxiliary equipment as chains, wire rope, slings,
hooks, and clips are designed for specific jobs and loads and should not he used in
other than design serv ices or at greater than design loads .
0 Tags on hoisting equipment or on supporting structures show the maximum load capacity
and the color code tape of the last proof-load test . Proof-load tests are conducted
by Maintenance every 6 months . Hoisting equipment not bearing the current color code
tag should not be used, and this condition should be reported to responsibl e
supervision .
FORK LIFT S
The use of fork lifts is limited to those who have been granted operator' s licenses
by the Safety Department . These are granted only after a demonstration of ability
to handle the equipment .
BLOCK AND TACKLE
Tackle is an assembly of ropes and blocks used to multiply force . The rope is reeved,
or threaded , through blocks which may have one or several sheaves . Simple tackle
consists of one or more blocks reeved with a single rope . Compound tackle is com-
prised of two or more blocks reeved with more than one rope . The pulling force is
applied to a single rope leading from the tackle system . The rope called the fall
line may be led through a leading block which is an additional block used to change
the direction of pull .
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NECHANICIS HANDBOO K
INCLINED PLANES
•
Inclined planes furnish a simple means of mechanical advantage . The mechanical
advantage is equal to the length of the inclined surface divided by the rise . The
grade is expressed in percentage of the rise divided by the horizontal length .
M. A. - A
A
A
GRADE 1%) z DO
Figure 8 .32 Inclined Plan e
CHOCKS
Chocks are used to prevent cylindrical objects from rolling . The effective height of
the chock is the highest point of contact with the cylinder . For safe design of
chocks the rule of thumb is : the effective height of the chock in inches should equal
the diameter of the cylinder in feet . For a 2-foot tank diameter , the effective height
the chock is 2 inches ; for 2 3-foot tank diameter , the effective height of the
chock is 3 inches .
Figure 8 .33 Chock Siz e
HAND SIGNALS -
Hand signals are used in winch and crane operation because of the distances and the
noise conditions of operation . Safe operation depends upon clear signaling by the
person directing and full understanding by the crane or winch operator . Figures 8 .34
and 8 .35 illustrate commonly accepted hand signals for crane and winch operation .
8-2 4

BNA0875869 2
H DMSp01659617
RIGGING
MAKE
MOVEMENT
SLOWLY
r4
• Figure 8 .34 Hand Signals for Crane or Swinging Boom Operation
8-2 5

BNA0875869 3
H DMSp01659618
MECHANIC'S HANDBOOK
RACK
zv
SIGNALS FOR TWO WINCHE S
Figure 8 .35 Hand Signals for Winch Operatio n •
8-2 6

BNA0875869 4
H DMSp01659619
• SECTION 9
ELECTRICITY
CONTENTS
Page
Making Electrical Measurements 9-1
Voltmeter 9-1
A®eter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Ohmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-i
Use of Volt Ohm Milliammeter (Triplett 630-A) . . . . . . . . . . . . . . 9-2

Measuring li-C Volts . . . . . . . . . . . . . . . . . . . . . . . . 9-t
Meaauring A-C Volta . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Measuring Il-C Resistance . . . . . . . . . . . . . . . . . . . . . . 9-6
Measuring O-C Current . . . . . . . . . . . . . . . . . . . . . . . 9-7
Measuring Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Measuring Output Volta (DE) . . . . . . . . . . . . . . . . . . . . . 9-9
Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Use of Simpson 260 Multi-Meter . . . . . . . . . . . . . . . . . . . . . 9-11
•
Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Resistors and Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Soldering Electric Connections . . . . . . . . . . . . . . . . . . . . . . . 9-1 6
Wire Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Shielded Wire Preparation . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Connector Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 0

BNA0875869 5
H DMSp01659620
ALEGTIIIC I1T
SAXINC ELECTRICAL MBASURE ANT S

•
Separate meters, o separate sections of combination meters , are provided for me r-

dhg alternating and, direct current. To avoid damage to the instruments , the proper
meter or meter section must be used .
Meters , or sections of combination meters , are also graduated for given ranges (milli,
mince, or units ) . The proper range must be used for the value to be measured . Where
the expected range is unknown , the meter should be set to read the highest values
likely to be encountered . If the first reading is too low to be measured on the scale
used, further readings may be taken by switching to a lesser scale on multi-range
meters or using a separate meter of lower range .
Before taking a reading , check the zero adjustment of the scale, especially if the
meter is moved from a horizontal to a vertical position . If the meter does not indi-
cate zero prior to use , the necessary- adjustment may be made by setting the adjusting
screw on the face of the meter. Meters should be read from directly in front of the
scale . Because of the size and arrangement of the scale graduations , errors can
occur if the meter is read at an angle .
VCLTMETE 1
A voltmeter may be used to measure the electromotive force applied to a circuit or it

may be used to measure the drop in voltage caused by a component in the circuit . It
is always connected across the circuit with the positive terminal of the meter con-
nected to the positive terminal of the circuit and the negative terminal of the meter
to the negative terminal of the circuit . Either meter terminal may be connected to
either circuit terminal to measure a-c voltage . Make certain , however, that the proper
type meter is used for the voltage measured , i .e ., an AC voltmeter for AC voltage
and a It voltmeter for DC voltage , as the two are not interchangeable .
•
ADf1ETS
An ammeter is used to measure current flowing through a circuit . It is connected in

series with the line delivering the current by breaking the line and inserting the
meter . As with the voltmeter, when used to measure d-c circuits , the meter must be
inserted to read in the direction of current flow . An ammeter will be damaged if it
is placed across a circuit rather than in series with a resistance of some type .
The type of ammeter used will be determined by the type of current measured as is the
case with voltmeters .
OE ME°DB
An ohmmeter is used to measure the resistance of a circuit or a component . It differs

from other meters in that the scale is graduated in unequal divisions and that full-
scale deflection reads mars ohms . Before connecting an ohmmeter into a circuit, the
voltage supplied to the circuit must be removed . To prevent damage to the meter, no
other voltage than that of the ohmmeter battery most be present . In addition to
measuring resistance , the ohmmeter may also be used to check circuit continuity . The
voltage source is removed from the circuit and the ohmmeter connected in series with
the line to be checked . The ohmmeter will indicate an open circuit as a high resist-
ance reading .
•
9- 1

BNA0875869 6
H DMSp01659621
NBCHANIC! S HANDBOOK
USE OF VOLT OHM MILLIAMPMT01l (TRIPIETT 630-A) FIGURE 9 . 2
There are f ive scales on the volt ohm milliammeter . The top red scale is used t o •
measure ohms . This scale is marked from 0 to 1K ( at left side ) . With the switch
knob turned to(1 x 1, the ohms scale is read exactly me it is marked . With the
twitch knob turned to 60 x 10 , the numbers on ohms scale must be multiplied by 10 .
Likewise , 11 x 1000 and 11 x 100 , 000 mean to multiply by 1000 and 100,000 respectively .
The second scale doom (black ) is used to read all d-c voltages . The third scale
(red) is used for all a-c voltages except the 3-volt range . The latter is read as the
bottom red scale (marked 3 at full scale) .
The lowest scale is used for all decibel measurements . The chart near the lower
right-hand corner of the dial is used in conjunction with the 103 scale as explained
under the heading Measuring Output Volts .
Below the meter dial is a small bakelite screw which can be rotated with a small
screwdriver to adjust the meter pointer to zero . For greatest accuracy the pointer
should always be on zero before making a measurement .
The large knob in the lower center of the panel is used to select all ranges . The
markings are self-explanatory .
Left of the knob is a recessed ADJ control used when making resistance measurements .
The jacks marked CON and V - Q - A are used for most measurements . (COM is negative)
The 630-A meter is accurate to within 1-1/2% of full scale reading on all DC ranges
except the 6000 volt range . The 6000 volt range is accurate within 3% . AC ranges,
except 6000 volt ranges , are accurate to within 2-1/2% when used on 60 cycle sine
wave voltages . The 6000 ACV range is accurate to within 3%. The resistance ranges
are accurate to within 1-1/2% of the scale length . Precision , non-aging resistors
insure lasting accuracy . All units are calibrated at 775 F. •
AC ranges are calibrated on a 60 cycle sine wave . Ranges should be chosen so that
readiega fall in the upper (right-hand) half of the scale . For greatest accuracy,
the instrument should be in the horizontal position wires it is read .
The Triplett 630-A Meter eovers the ranges shown in Figure 9 .1 .
DC volts . . . . . . . . . . . . . . . . . . . . . . 0-3-12- 60-300-1200-6000 at

20,000 ohms per volt
AC volts . . . . . . . . . . . . . . . . . . . . . . 0-3-12-60-300-1200-6000 at
5,000 ohme per volt
DC microamperes. . . . . . . . . . . . . . . 0-60 at 250 ms .
DC milliamperes. . . . . . . . . . . . . . . 0-1 .2-12-120 at 250 mu .
DC amperes . . . . . . . . . . . . . . . . .. . . .
0-12 at 250 mu .
Ohms . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1000- 10,000. . . . . . . . . . . . . . . . .
(4 .4-44 at center scale)
Magohoee . . . . . . . . . . . . . . . . . . . . . . . 0-1-100 . . . . . . . . .(4400 -440,000
at center scale )
Output volts . . . . . . . . . . . . . . . . . . 0-3-12-60-300-1200 a-c at 5 .000
ohms per vol t
Decibels . . . . . . . . . . . . . . . . . . . . . . - 30 to +4 , 16, 30, 44, 56, 70
on 500 ohm line.
Figure 9 .1 Triplett 630-A Meter Range s
9- 2 •

BNA0875869 7
H DMSp01659622
ELECTRICITY
SERVIC E
CAUTION ON IIGH VOLT S
6000
• 1200
Figure 9 .2 Triplett 630-A Volt -Uhm Milliammeter
•
9- 3

BNA08758698
H DMSp01659623
MECBANSC ' S HANDBOOK
Measuring 0-C Volts •
The selector switch is rotated to the appropriate range for d-c volts, starting with
the highest range if there is doubt as to the approximate voltage . For greates t
racy, ranges should be hosen as that readings fall in the upper (right hand)
half of the scale . (Figure 9 .3• )
For all ranges up to the 6000/1200 volts range , the black test lead most be plugged
into the CON jack and the red lead into the V- IZ -A jack . When 1200 to 6000 volts
are to be measured , the selector switch must be set on the 6000/ 1200 range , the red
lead most be plugged into the jack marked 6000 DCV, and the black lead plugged into
the jack marked CON.
The test prods are then connected across the voltage source . The red lead is,positive ;
if the seter reads backwards, polarity has been determined in error and the lead s
must be reversed .
All d- c voltages are read on the top

(black) scale . All scales are sot
marked exactly the same as the range
indicated by the knob position . Thus
0-3 volts is read on the 0-300 scale
by dividing by 100 (omitting two
zeros ) on all readings . The 0-1200
range is read on the 0-12 scale by
adding two zeros , and the 0-6000
range is read on the 0-60 scale by
adding two zeros .
The high sensitivity of 20,000 ohms

par volt allows measurement i
low-current grid and discriminator
circuits .
NOTE :
Do not handle either tester
or leads when they are con-
nected to high voltages .Make
certain that no condensers
are charged to a high voltage .
Figure 9 . 3 Measuring DC Volts
•
9- 4

BNA0875869 9
H DMSp01659624
ELECTRICITY
• Measuring A-C Volta
To measure e- voltage up to 300 volts, the black test lead is plugged into the CON
jack and the read lead into the V -fl -A jack . The selector switch is rotated to the
appropriate range, starting with the highest range if there is doubt as to the approxi
mate voltage . For greatest accuracy, readings should fall in the upper (right-hand
half of the scale . (Figure 9 .4 . )
When 1200 to 6000 volts are to be measured , the selector switch is set on the
6000/1200 range, the read lead is plugged into the jack marked 6000 ACV, and the black
lead is plugged into CON .
The test prods are then connected across the voltage source . As there is no polarity
on a-c, the red and black leads may be interchanged without causing the meter to read
backwards .
The two lover red scales are used for

a-c voltage readings ; the bottom
scale is used only for the 0-3 range .
When the 0-1200 a-c volt range is
used , two zeros are added to the 0-12
scale . When the 6000 volt range is
used, two zeros are added to the 0-60
scale . Na correction for frequencies
is necessary from 25 cps to 1000 cps .
NOTE :
•
Do not handle tester
or leads when they are
connected to high
voltages .
Figure 9 .4 Measuring AC Volt s
9- 5

BNA08758700
H DMSp01659625
MECHANIC'S HANDBOOK
Measuring 0-0 Resistanc e

To measure d-c resistance , the selector switch is rotated to the appropriate range •
for ohms . (Figure 9 .6 .) This range is determined from Figure 9 .5 •
To read Set switch to
0-1000 ohm . . . . ... . . . . . . .. . . . ... . . . x 1

0-10,000 . . . . . . ... . . . . . . .. . . . ... . . . x 10
0-1 Meg . . . . . . .. . . . . . . . . .. . . . .. . . . . x 1000
0-100 Meg . . . . .. . . . . . . . . .. . . . .. . . . . x 100,000
Figure 9 .5 Selecting Proper Range to Measure D-C Resistanc e
The black test lead is plugged into the CON Jack and the red lead into the V- 2 -A
jack .
The test prods are shorted together and the ADJ knob adjusted until the meter pointer
reads 0 on the top red ( (2 ) scale . (The 0 for the ohms scale is at the eztrem e
right side of the scale .) The 0
netting should be checked each time
an ohm range is changed .
The test prods are then connected

across the resistor . If the resistor
is wired in a circuit, one end of the
resistor is disconnected before a
reading is taken.
The basic scale 0-1K (0-1000) is used

for reading on all ohm ranges by
multiplying the scale numbers by 1,
10, 1000, or 100,000 as indicated by
CAUTaN ON NIGH oars •
the selector switch setting .
0
In the measurement of resistance, a
current is passed through the un-
known resistor . Generally this current
is so small as to be negligible . How-
ever on the 0-1000 range fairly high
current is employed which could dam-
age the fragile circuits being meas-
ured .
The current drain from the 1 .5 volt

battery is 170 MA on ohm position xl
reading approximately center scale
(4 .4 ohms) . Use of one of the higher
ohm ranges for general continuity or
circuit testing will give much longer
masoa N
battery life .
eeaiTON
Risen the seals of an ohmmeter is non-
linear, the accuracy of the reading
cannot be expressed as a percent of
full scale . Ohmmeter accuracy is
generally referred to a linear scale
such as the d-c volt scale . Thu s
Figure 9 .6 Measuring TC Resistanc e
`-1-1/2 ohms accuracy means an allowable
=.9 divisions on the d-c scale . For
example , 2 ohms could read from about 1 .05 to 2 .2 ohms and be within tolerance .
Metal parts of the circuit should not be touched when high ohm ranges are being used
since body resistance can cause serious error . •
.6
0
CONFTDFNTTAT . l,EVEl, T- ITNDETO PROTECTTVF. O12DE12 ,

BNA0875870 1
H DMSp01659626
ELECTRICITY
Measuring D-C Curren t

•
To measure d-c current, the black test lead is first plugged into the V- Q -A jack .
The selector switch is then rotated to the appropriate range for d-c circuit, start-
ing with the highest range if there is doubt as to the approximate current . Readings
should fall in the upper ( right-hand ) half of the scale for greatest accuracy . (See
Figure 9 .7 . )
The test prods are then connected in series with the circuit to be measured . Con-
necting the prods in parallel with any part of the circuit may burn of the meter and
the shunt . If, in the initial reading the meter reads backwards , polarity has been
determined in error . This is corrected by reversing the leads . The electrical
power must be connected to the circuit . Neither the meter nor the leads should be
handled while they are attached to high voltage circuits .
All current ranges ( including microamperes , milliamperes , and amperes ) are read on
the upper black scale . When the 1 .2 ma range is required , the 0-12 scale is used and
divided by 10 . When the 120 ma range is required , the 0-12 scale is used and multi-
plied by 10 .
When the 60 microampere range is used,

meter readings may va ry from calcula-
tions . This may be caused by moisture
or by a slight potential caused by the
soldering or joining of dissimilar
metals . Also, fumes or liquid acids
or alkalies reacting with metal parts
of the circuit may generate slight
currents , In addition , contact by the
body upon metal parts of the meter or
circuit can promote electrical dis-
• turbances .
Figure 9 .7 Measuring DC Current
9-7

BNA0875870 2
H DMSp01659627
MECHANIC'S HANDBOOK
•
Measuring Capacity
The 630-A meter can be used to measure capacity by the arrangement shown in the
accompanying figure where it is set up as an a-c voltmeter . The following chart can
be used to determine the correct a-c voltage range . The selector switch must be
initially set on the 300 volt range since, if the condenser is shorted, serious
damage may result to the meter on a low recge setting . ( see Figure 9 .8 . )
To Set Deflectio n
measure selector i n
Irfd switch to a-c volt s
.002 .4 5
.004 .8 3
.006 3 ACV 1 .2 5
.008 1 .6 5
.010 2 .1 0
.020 4, 3
.04 12 ACV 7.7
.05 9.7
.08 14 . 5
.10 17 . 5
•
.2 60 ACV 30 . 0
.4 45 . 0
.6 57 . 0
1 .0
2 .0
5 .0
10 .0
.s
i NOTE :
300 ACV
65 . 0
75 . 0
85 . 0
95 . 0
100 . 0
20 not perform this test Figure 9 .8 Measuring Capacity

on electrolytic condensers .
9- 8

BNA0875870 3
H DMSp01659628
kLLCT[tICITY
Output Volts (Do )

• Measuring
in units called the decibel, a term used to indicate

Output is generally measured
work, The DB scale on this meter is based on
power levels is amplifiers or telephone .
ohm line when .006 watts is dissipated in the line
the voltage developed across a 500 is based on .001 watt
These should not be confused with the VU (volume unit) which
with a meter having special ballistic
dissipated in a 600 ohm line and is measured
characteristics . (See Figure 9 .9 . )
output volts (DB) the selector switch is rotated to the appropriate a-c
To measure
chart on the meter dial . The higbest range should
volt range indicated by the small number of decibels .
be selected initially if there is doubt as to the approximate
the plate circuit or speaker voice coil .
The test prods are then connected across
by plugging the black
When d-c voltage is present in a circuit, output is measured
jack. The d - c current is then
lead into the 1015 jack end the red lead into the output impedanc e
which is installed in series . This condenser
blocked by a .1 pfd condenser
is disregarded in most measurements .
Where no d -c is present , output volt-

age can be read accurately by using
this meter as a regular a-c voltmeter
(i .e ., by plugging the red lead into
the V- fl -A jack instead of output) .
All DB ranges are read on the bottom

black scale using the small chart on
the meter dial . For example, when
the selector switch is set cu the 3-
volt a- c range, the DB scale is read
direct. However , when the indicator
is set an the 12 a-c volt range, 12
•
must be added to each number on the
DO scale . Than, with the meter read-
ing -2 , the actual DO reading will be
+10 DO . If line impedance is not 500
ohms ( as in speaker voice coils), the
readings will be only relative, ant
actual, DB .
)
Figure 9 .9 Measuring Output Volts (DO
Operation Char t
of the Triplett 630-A volt- ohm milliemmeter .

Figure 9 .10 shows the correct usage
•
9-9

BNA08758704
H DMSp01659629
To Set selector Plug red* test lead Read Each scal e
measure switch to in jack marked on div . equal s
D-C volts Black .eel s

0-3 3 M' V- n -A 0-300 DC . 100 0 .05 vol t
0-12 12 DCV V- 11 -A 0-12 DC X 1 0 .2 vol t
0-60 60 DCV V- 11-A 0-60 DC X 1 1 .0 vol t
0-300 300 DCV V- 11 -A 0-300 DC X 1 5 .0 volt s
0-1200 1200/6000 DCV V- Si -A 0-12 DC X 100 20 .0 volt s
0-6000 1200/6000 DCV 6000 DCV 0-60 DC X 100 100 .0 volt s
A-C volts Red scal e

0-3 3 ACV V- 11 -A 0-3 AC K 1 0 .05 vol t
0-12 12 ACV V- 11 -A 0-12 AC X 1 0 .2 vol t
0-60 60 ACV V- U -A 0-60 AC X 1 1 .0 vol t
0-300 300 ACV V- 1l -A 0-300 AC X 1 5 .0 volt s
0-1200 1200%6000 ACV V- 11 -A 0-12 AC X 100 20 .0 volt s
0-6000 1200,6000 ACV 6000 ACV 0-60 AC X 100 100 .0 volt s
D-C current Block scal e

0-60 eta DC 60 F. V- tl -A 0-60 DC X 1 1 .0 p a
0-1 .2 Me DC 1 .2 DCMA V- 11 -A 0-12 DC - 10 0 .02 M a
0-12 Me DC 12 DCMA V- R -A 0-12 DC X 1 0 .2 M a
0-120 Me DC 120 DCMA V- 11 -A 0-12 DC X 10 2 .0 M a
0-12 AMPS DC 12 AMP V- C1 -A 0-12 DC X 1 0 .2 AMP
Ohm . Eac h scale division equals ( in ohms )

0-1000 12 X 1 V- f1 -A
0-10,000 11 1 10 V- 11 -A Red 0- 4- 5- 10- 20- 50-
0-1 Meg 0 .1 1000 V- A -A scale 4 5 10 20 50 20 0
0-100 Meg n 1 100, 000 V- 11 -A
Decibels Xl .1 .2 .5 1 5 50
-30 to +4 3 ACV Output 1(10 1 2 5 10 50 50 0
-18 to +16 12 ACV Output 1(1000 100 200 500 1K 5K 50 K
-4 to +30 60 ACV Output 1(100,000 1011 20K 50K 100K 500K 5 Meg
.1 0 to + 44 300 ACV Outpu t
+22 to +56 1200/6000 ACV Output *Blaek test lead plugged in CO M
+36 to +70 1200/6000 ACV 6000 ACV jack for ail measurement s
Figure 9 .10 Triplett 630-A Volt Ohm Milliommeter Operation Char t
0 is 0
ELECTRICITY
• USE OF SIMPSON 260 MULTI-METER
The Simpson 260 Multi-Meter is used in circuit analysis to measure voltage, current,
and resistance . Figures 9 .11 and 9 .12 show the meter and the correct usage of the
meter .
SERVICE DU E
-10A . 'oo tEl il.yt 41. +IOA .
A.C. 500 M . A . --% I r- 100 Y .A .

OUT
PUT\
! D .C . 2 52.
6
ICY .
__Y 6'
~IO
~'~ 10 0
vi
ZE0000H
zoe Micso .we s

SOD. Rx l
zsoe
250V . RICI00
++0 08
00 N011 1000 V. L,_ RX10.000
+ 5000 v.
+52 oe ~
• Figure 9 .11 Simpson 260 Multi-Meter
9-11
CONETDENTTAT, T,EVET, T - ITNDER T'ROTECTTVE ORDER ,

BNA08758706
H DMSp01659631
MECHANIC IS EAMDDOOK
AC-DC •
Value to switch Range selector
be read Plug positions pos . switch pos . Scale to read
2 V DC Common & + DC 2 .5 V 0 to 250 V DC ,

divide by 100
28 V DC Common & + DC 50 V 0 to 50 V D C
300 V DC Common & + DC 1000 V 0 to 10 V DC ,

multiply by 100
5000 V DC Common & DC 1000 & 5000 V 0 to 50 V DC ,
5000 V DC multiply by 100
3 V AC Common & + AC 10 V 0 to 10 V AC
26 V AC Common & + AC 50 V 0 to 50 V A C
115 V AC Common & + AC 250 V 0 to 250 V AC
5000 V AC Common & AC 1000 & 5000 V 0 to 50 V AC

5000 V AC multiply by 100
Continuity Common & + DC RX1 0 to 214 ohms

(zero adjust )
1 to 99 ohms Common & + DC RX1 0 to 214 ohms
(zero adjust )
100 to 10,000 Common & + DC R X 100 0 to 2M ohms ,
multiply by 100
(zero adjust)
Deer 10,000 Common & + DC R X 10,000 0 to 2M ohms ,
multiply by 10,000 •
0 to 10 amps -10 A & +10 A DC 500 MA 0 to 10 D C

DC
Milliamperes Common & + DC 500 MA 0 to 50 DC ,
multiply by 1 0
Microamperes Common & + DC 100 Micro-p
. 0 to 10 DC ,
multiply by 1 0
DB Values Co mm on & + AC 1 of 5 DB - 12 to +3 9
0
Position s
Figure 9 .12 Simpson 260 Multi-Meter Operation Char t
Precautions for meter protection :
1 . Circuit power must be off before checking for continuity or measuring resistances .
2 . Always connect the meter in series when reading milliamperes or amps .
3 . When doubt exists as to the values to be measured , set the range selector switch
to the highest value first .
4 . Report a defective meter immediately to instrument laborato ry.
9-1 2

BNA0875870 7
H DMSp01659632
ELECTRICITY
•
RESISTORS AND CAPACITOR S
The color of the bands or dots on a resistor or capacitor are codings which reveal
resistance in ohms ( Il ) or capacitance in micromicrofarads ( R gfd ) . The voltage
rating of a resistor or capacitor can be determined only by referring by part number
to manufacturers ' specifications .
The colors of the first two bands (or dots) represent the first and second digits of
the resistance or capacitance . The following RETMA color code (Figure 9 .13) shows
the values of the different colors . Thus a green band (5) and a red band (2) repre-
sent the number 52 .
The color of the third band ( or dot ) represents the value of the multiplier used with
the first and second digits . If a green band ( 5) and a red band (2) were followed
by a third yellow band (10K), the velne represented would be 52 x 10 K or 520,000 .
The fourth color band indicates the tolerance . The absence of the fourth band indi-
cates a tolerance of 20K .
Fifth and s ix th color bands are employed on capacitors only . They give the voltage
in hundreds of volts . Thus if the colors of these bands were red and orange, they
would represent the digits 2 and 3 . As these colors represent voltage in hundreds of
volts, red and orange represent 2300 volts .
Additional bands , represented by the letters G, R, I, and J in Figure 9 .14 are manu-
facturer ' s endings . They indicate classes and temperature coefficients . These
values are not shown on the Table and must not be considered when the color bands of
ceramic radial lead, axial lead, and standoff capacitors are being interpreted .
9-1 3

BNA08758708
H DMSp01659633
Resistors Molded paper capacitors Molded mica capacitors Ceramic capacitors
Color Digit Multiplier Tolerance Multiplier Tolerance Multiplier Tolerance Multiplier Toleranc e
±20%
Black 0 1 1 ±20% 1 ±20% 1 r 2 .0 pF fd -
Brown 1 10 10 10 10 ±1 %
Red 2 100 100 100 ±20% 100 ±2%
Orange 3 1K 1K 1K *-3% IK ±±2 .5%
Yellow In lox 1OK ±5% 10K 1OK
Green 5 100K ±5% 156

or 0 .5 µµfd*
Blue 6 1000K
Violet 7 10,000 K
Gray 8 100 ,000K 0 .01 10 .25 µµfd*
White 9 1,000 , 000K ±10% 0 .1

77-
or 1 . 0 pµfd*
Gold 0 .1 15% 0 .1 ±56 0 .1 156, .
Silver 0 .01 1106 ±10% 0 .01 110%
None ±20% ±206
Resulting value . are in ohms for resistors , "K" indicates thousand . *Capacitence less than
and in µµfd for capacitors 10 p1if d
Figure 9 .13 RETMA Color Code for Resistors and Capacitor s
• • 0
ELECTRICIT Y
IRES STOR TYPES ANDK

MA R ING S
•
ABCD DD AT CS 8
CAPACITOR TYPES AND MARKING S
MOLDED PAPER MOLDED MICA CERAMI C
GDOT
TUBULAR: RADIAL LEAD:
RETMA; JAN :
A J_
AB AB
I t lll ~
ABCD EF 00 00
XJABC D
0 0 0 0 0 (6 COLOR)
GD C G D C
WHITE BLACK Itli t

HABC D
BUTTON SILVER MICA :
IS COLOR)
FLAT JAN TYP E :
G A AXIAL LEAD :
D g
3rd DIGIT
SILVER 'at
e
OBSOLETE RMA SYSTEMS: HA8C D
•
A B 3rd DIGIT
:iffF STANDOFF :
OO O
E D C
E A B C ~~~~
FLAT COMMERCIAL TYPES :
000
0 HA B C D
000 O O
A 8 C E D
E BLANK
O
DISC :
fll D E D p B IC
76-7-1
O O O
BLACK
A B C A 8 C
E (3 COLOR)
ABC C
A B
ABC D O O O O
O
X D
E D
FRONT REAR (5 COLOR)
• Figure 9 .14 Table of Resistors and Capacitor s
9-1 5

BNA0875871 0
H DMSpO1659635
MEC9ANIC'5 HANDBOOK
•
SOLDERING ELECTRICAL CONNECTIONS
Soldered joints are often used in electrical and electronic circuits and if properly
made , make more reliable connections than most mechanical devices . An acceptable
soldered join ,,, however , requires proper techniques and correct materials .
Surfaces to be soldered or tinned must be free of oxides , scale , oil, and other for-
eign matter . This cleaning should be performed just before flux is applied . Rosin
is the only flux acceptable for use in instrumentation work . It may be either a
liquid rosin flux or a rosin core solder . Eventual corrosion of circuit components
will occur if acid fluxes are used because of the difficulty of removing all traces
of flux from the finished joint . In a few instances , acid flux may be required but
may be used only with permission of the Instrumentation Engineer in charge .
Whenever possible , surfaces to be connected by solder should be tinned before being

joined . Tinning makes surfaces easier to join and results in more positive connec-
tions . Before acceptable tinning can be achieved , the iron itself must be properly
tinned . First one side of the hot iron is cleaned, exposing the metal . Rosin core
solder is applied i mmediately. The process is repeated for the other soldering faces,
excess solder being wiped off with a clean rag . The iron should also be wiped fre-
quently during soldering operations .
Solder is always applied to the work , not to the soldering iron . Before the solder-
ing operation is attempted , the iron should be clean, properly tinned, and heated to
the proper working temperature . The iron should be held against the parts to be
joined until the solder flows smoothly and envelope the work . Movement of the parts
before the solder has solidified will result in a "cold joint ," which has a white
appearance rather than the normal shiny silver . Cold joints tend to be of high
resistance and may have a bad effect on the circuit . See Figure 9.15 for proper
application of solder to contact pins .
•
Figure 9 .15 Method of Applying Solder

to Contact Pius
9-16

BNA0875871 1
H DMSp01659636
ELECTRICITY
0 WIRE PREPARATION
The correct preparation and tinning of wire prior to soldering it to a component is

one of the basic steps in securing a good soldered connection . Wire strippers most
be adjusted so that none of the strands of wire are cut or damaged in any way . If
the wire is damaged , it might ultimately be the cause of a wit failure in the
finished installation .
When stranded conductors are stripped , the strands have a tendency to unwind . If this
condition occurs, the strands should be twisted back into their former position prior
to tinning . After wire has been stripped and all frayed strands twisted back into
place , it is ready for tinning .
A small amount of solder should be applied to the tip of the iron . The wire is then
placed on top of this solder and allowed to heat . When the wire has reached the tem-
perature of the iron , solder will flow into its strands . At this time a small amount
of solder is applied to the wire , not the iron . Solder is then allowed to flow until
the wire has absorbed enough to tin eve ry strand . Only enough to accomplish this
purpose must be used . Too much solder will increase the diameter of the wire and will
prevent it from passing through the hole in the lug . Too much solder will also make
it hard to form around the lug . Too little solder will allow the strands to fray and
will result in a poor connection .
To prevent the wire from separating from the terminal under vibration and shock con-
ditions, the following precautions should be observed :
1 . The wire lead must be protected from damage during installation . Sharp bends
should be avoided .
2 . The lead must be wrapped sufficiently around the terminal . The lead wrap should
• be at least three-quarters turn but not in excess of one complete turn .
3 . The lead must allow a small degree of flexibility .
Typical methods of wrapping are shown in Figure 9 .16 .
9-1 7

BNA0875871 2
H DMSp01659637
MkxHAISIC,s UAMDBOOIC
Hook terminal .
Flat terminal when approached from the end .
Both prongs of a bifurcated terminal
Hook Splic e Turret terminal s
9-18
Figure 9.16 Methods of Wrapping Wire Around Terminals or Splice s
i
CDNFIDENTLVL LEVEL I- UNDER PROTECTIVE ORDER ,

BNA0875871 3
H DMSp01659638
ELECTRICITY
• SHIELDED WIRE PREPARATION
Shielded wire is often used in instrumentation circuits and requires special prepara-
tion, i .e ., one end of the shield of this type of wire being grounded by pigtailing,
while the other end is terminated by insulating it from possible grounding .
In the pigtailing operation , the outer covering of the shielded wire carefully
removed, care being taken not to damage the shield . The shield is then pushed back
from the conductor or conductors and the strands of the shield carefully separated
with a scribe . The inner conductor is then worked through the shield at the point
where the strands are most separated , and the shield is bent to one side . The shield
is next cut to approximately 3/8 in . Using a heat shunt, the shield is them soldered
to the ground wire .
As shown in Figure 9 .17, a piece of Temflex is inserted over the conductor or con-
ductors and tied . A larger piece of feistier is installed over the entire connectio n
and tied .
Figure 9 .17 Shielded Wire Preparatio n

•
One method of so terminating an ungrounded shield is shown in Figure 9 .18 and con-
sists of the following steps : ( 1) The outer nylon jaoket is cut back about 7/8 in .
from the end of the wire . ( 2) The metal shield is cut back as shown below, care
being taken not to damage the inner nylon jacket ( 3) Tha desired longtb of inner
nylon jacket is then removed , using the correct wire stripper .
CUTBACK SHIELD
CUTBACK INNER
CUTBACK OUTER NYLON JACKE T
NYLON JACKET- cCONDUCTO R
_ 7/8a APPRO X
SHIELD PUSHED BACK
OVER OUTER JACKET
SLEEVING
SPOT TIE
SPOT TI E
I r" I/B' MI N
I12e MIN --+4.-~ I/8" MIN
Figure 9 .18 Method of Terminating Ungrounded Shield

•
9-1 9

BNA0875871 4
California, No. CC 97-1554
H DMSp01659639
•
CONNECTOR PREPARATION
The most commonly used connectors in electronic assemblies are Cannon and Winchester
plugs and receptacles . The major cause of failure in these connectors is poorly
soldered wires . Special care should be taken to fill the solder pots of these con-
nectors and to prevent the rosin flux from sinking to the bottom and taking up space
that should be filled with solder . A poorly filled solder pot is subject to crackin g
under vibration. The wire may come loose , resulting in a poor electrical connection
which might ultimately result in the failure of a whole unit . To obtain a correctly
filled solder pot, solder must be fed slowly . See figure 9 .19 for correct method of
preparing connector for soldering .
•
Figure 9 .19 Preparation for Soldering on Connector s
To properly solder a cable to a connector the following procedure is recommended :
1 . Strip the wire and insert it in the pot - when bottomed , approximately 1/j2" o f
the wire should be exposed above the pot, (see figure 9-20) . Cut wire to fit .
2 . Install insulation tubing above the exposed end of the wire .
•
Figure 9 . 20 Joining Cables to Connector s
9-20

BNA0875871 5
H DMSp01659640
ELECTRICITY
3. Tin the entire length of the stripped wire that is to be i erted in the pot of
•
the connector . The insulation must not be discolored or curled by this opera-
tion .
4 . Insert a small piece of solder in the pot of the connector .
5 . Place the iron tip on the back of the pot . When the solder melts and bubbles ;
insert the conductor into the pot until it is bottomed . If necessary, apply a
small amount of solder to the joint ( see Figure 9 .19) .
6 . Remove the iron and hold the conductor steady until the solder cools and hardens .
The contour of the individual strands of wire should be easily seen when the
solder has cooled .
7 . Clean the joint using an axid brush dipped in Isopropyl Alcohol to remove flux
residues .
S . Slip the insulation tubing over the soldered connection .
•
9-21

BNA0875871 6
H DMSp01659641
0
SECTION 1 0
HAND TOOLS
CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Hacksaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Micrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Vernier Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Bench Grinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Holding Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
P . .be. and Punching . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Chisels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Hammer . . .
Shears and Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
Screwdrivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 3
. . . . . . . . . . . . . 10-33
Open -End Wrenches . . . . . . . . . . . . . . .
• Box Wrenches 10-35
Combination Box and Open -End Wrenches . . . . . . . . . . . . . . . . . . 10-35
Striking Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Set Screw Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Socket Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Adjustable Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Pipe Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 9
Threads, Taps and Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Combination Square . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Protractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 1
Tube Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
Tube Benders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
Tube Flaring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
Grip Die . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44

Flaring Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45

BNA0875871 7
H DMSp01659642
HAND TOOLS
INTRODUCTION
Tools are the mechanic ' s best friend . Regardless of the type of job to be done, a
mechanic should choose and use the rr c ect tools . Particular care should be take n
to preserv e them if they are to last . Improper use of tools can cause personal
injury , damage to equipment , or damage to the tools .
HACKSAWS
FRAME TYPES
1 . Solid
2 . Adjustable ( 8 to 16 inches )
BLADE TYPES
1 . Hardened and tempered tool steel (Molybdenum steel is best blade) .

A. All hard ( Full blade temper )
Used on large sections of steel and on skilled work where accuracy

is needed .
B. Flexible ( Only teeth tempered)

General purpose blade .
2 . Pitch ( Number of teeth per inch ) ( See Figure 10 .1)
• A . 14--Pitch, for mild soft material .

B . 18--Pitch , for tool , high carbon and high speed steels . (General
Purpose Slade )
C . 24--Pitch, for angle iron, brass , copper, and iron pipe .
D . 32--Pitch , for thin sheet metal , and this wall tubing .
3 . Set ( Offset of teeth on blade)

A . Alternate ( Most common )
Teeth lean off to side of blade alternately ; one to one aide other to
other side . General purpose set, used on all materials .
B . Raker
Every third tooth is straight up and down . Used on material where clog-
ging of teeth is a problem .
C . W-
Teeth curv e from side to side . Used mainly on 32-pitch blades where a
precision cut is needed .
Note : The set of a blade is for the blade ' s clearance in cutting .
•
10-1

BNA0875871 8
H DMSp01659643
MECHANIC'S HANDBOOK
CORRECT INCORREC T
14 TEETH
FOR MILD MATERIAL
LARGE SECTIONS
PLENTY OF CHIP FINE PITCH,TEETH

CLEARANC E CLOGGED, NO CHI P
CLEARANCE
18 TEETH
FOR TOOL STEE L
HIGH CARBON
HIGH SPEED STEEL
PLENTY CF CHIP FINE PI TCH,TEErH

CLEARANCE CLOGGED, NO CHI P
CLEARANCE
24 TEETH is
FOR ANGLE IRON, BRASS,
COPPER, IRON PIPE, ETC.
COARSE PITCH
MORE ON SECTION STRADOLES WORK
STRIPPING TEETH
32 TEETH
FOR CONDUIT 8
OTHER THIN TUBING,
SHEET METAL
TWO TEETH OR COARSE PITCH
MORE ON SECTION STRADDLES WOR K
THE BEST RESULTS ARE OBTAINED BY SELECTING THE CORRECT PITCH FOR
GENERAL PURPOSE WORK, IB TEETH PER INCH IS RECOMMENDE D
Figure 10 . 1 Hack Saw Blade s
10-2

BNA0875871 9
H DMSp01659644
HAND TOOLS
•
USE OF RACKSAW
1 . Teeth should face away from handle when blade is in frame . (See Figure 10.2)
2 . Force applied only on the forward stroke, approximately 32 strokes per

minute .
3 . For deep cuts use a deep frame hacksaw .
4 . Rule of Thumb :
A . On soft material--use blade with fewer teeth .

B . On hard material -- ase blade with more teeth .
C . On thin material--use blade with many teeth .
Note : Never use hacksaw with a rapid motion , heat removes temper from
teeth .
CORRECT MANNER FOR STARTING

BLADE IN WOR K
1 . KEEP GOOD TENSION ON BLAD E
2. USE VERY SNORT STROKES .
Figure 10 . 2 Use of Hack Saw
•
10- 3
CONFID ENTIAL LEN EL I - UNDER PROTECTIVE ORDER ,

BNA08758720
H DMSpO1659645
MECHANIC'S HANDBOOK
•
FILE S
Files are hardened steel tools used for cutting , removing , smoothing or polishing
metal . The tang is the only part of a file not tempered . ( See Figure 10 .3 . )
TERMS
1. Coarse
2. Bastard
3. Second cut
4. Smooth
5. Dead smoot h
CLASSIFICATIONS
1 . Flat Bastard File----------------Used for general purpose rough filing .

2 . Mill File ( second cut ) --Used- for removing a small amount of metal and
making the filed surface smooth .
3 . Half Round Bastard File---------- The rounded face of this file is used to file
a surface having a large concave radius . The
flat face can be used for general purpose rough
filing.
4 . Round Bastard File---------------Used for enlarging holes, also for filing sur-
faces having a small concave radius .
3 . Smooth Mill File-----------------Used for all work where surfaces are flat or
convex.
6 . Half Round Second Cut File-------Used some as half round bastard file but on •
work where there is not so much metal to be
removed .
7 . Three-Square or Triangular File--Very useful for filing small notches, square or
cornered holes , and for cleaning up burred
threads .
8 . Round Smooth File---------------- Used same as round bastard file, but on work
where there is not so much metal to be removed .
SELECTING CORRECT FIL E
1 . For heavy rough cutting , a large , coarse, double cut file .

2 . For finishing cuts , use a second out or a smooth single out file .
3 . When filing cast iron, start with a bastard cut file and finish with a second
cut file .
4 . When filing soft steel, start with a second cut file and finish with a smooth
cut file .
5 . When filing hard steel, start with a smooth cut file and finish with a dead
smooth file .
6 . When filing brass or bronze , start with a bastard cut file and finish with a
second cut file .
7 . When filing aluminum, lead or babbit metal , use a bastard file .

8 . For small work use a short file ; for large work use a file as large as can be
controlled conveniently .
NOTE : Apply pressure ou forward stroke only on all files .
•
10-4

BNA08758721
H DMSp01659646
HAND TOOLS
DOUBLE CUT
SINGLE CUT
DIFFERE NT SHAPE S
ROUN D HALF ROUN D

FLAT SQUAR E
MIL L
L~J l CABINET
KNIFE EDGE 3-SQUARE CROSSING
PILLER
_SINGLE CUT
•
IN ~ WE
N MENNUMME"I
COARSE BASTARD SECOND SMOOTH DEAD SMOOTH
an on m-, as
DOU BLE CUT
,222227Z-ti
SINGLE
- CUT
Figure 10 .3 Parts of a Fil e
•
10-5

BNA0875872 2
H DMSp01659647
MECHANIC ' S HANDBOO K
THE USE AND CARE Or FILE S
1 . Before attempting to use any file, it should be equipped with a tight fitting
handle . Using a file without a handle could result in a painful injury , should
the file meet am obstruction forcing the sharp end of the tang into the hand .
2. To put a handle o a file ; first, make s re the handle is the right sr and
that the hole is large enough for the tang . Insert the tang into the hole in
the handle then tap the back end of the handle on the bench . Make sure the
handle is on straight . ( See Figure 10 .4 . )
3. To remove a file handle ; hold the handle in your right hand, hold the file with
your left hand, and give the ferrule end of the handle a sharp rap against the
edge of the bench . The ferrule is the metal sleeve on the hole ead of the
handle .
4 . Whenever possible , the part to be filed should be clamped rigidly in a vise .

The teeth on a file are so arranged to cut when the file is moving in one direc-
tion only . The forward stroke is the cutting stroke , and all file pressure
against the work should be relieved on the back stroke .
The teeth are set at an angle across the face of the file and slanting toward
the tip of the file . (Figure 10 . 4 .) On a single-cut file, the teeth are cut
at an angle of 65 to 85 degrees to the centerline . Oa double -cut files the
angle of the first set of teeth usually is 40 to 50 degrees and the crossing
teeth 70 to 80 degrees . Proper methods of holding a file are shown in Figure
10 .5 .
5 . Never use a file after the teeth become " choked" with particles of metal . Oc-
casional bumping of the file against the bench will jar loose the filings which
stick in the teeth . If the teeth get too loaded , it is best to clean the teeth
with a file card. This is a brush with short , stiff, wire bristles . (See •
Figure 10 .4 . )
6 . Don't throw files around an a bench or into a drawer with other tools and expect
them to stay sharp .
7 . Keep files away from moisture and water to prevent rusting .

8 . Never use a file for prying . A light bending force will snap it in two .
9 . Never hammer on a file . This is dangerous because it may shatter with chips
flying in eve ry direction .
Pigure 10 . 4 Use and Care of File. •
10- h

BNA08758723
H DMSp01659648
HAND TOOL S
10- 7

BNA08758724
H DMSp01659649
MECHANIC'S HANDBOOK
DRILLS •
1 . Common devices for holding twist drills :

A . Hand brace ( egg beater )--------------------(For holes with
no need
B . Breast drill brace------------------------- for accuracy)
C . 1/4, 3/8, 1/2 drill (electric or air pressure )
D . Drill press (machine)
2 . Types of twist drills :

A . Carbon stee l
B . High speed stee l
3 . Parts of a drill : ( See Figure 10 .6 .)

A . Body (flute or spiral )
B . Shank (drill size stamped on it)
C . Poin t
4 . Drill sizes : ( are measured either in fractions , numbers, or letters ) ( Refer to

Figure 10 .9 . )
A . Number drills :
1 . No . 80 ( smallest diameter ) .0135-inch diameter
2 . No . 1 ( largest diameter ) . 228-inch diameter
B . Fractional drills :
1 . 1/64-inch increasing in 64ths up to one inch .
C . Lettered drills : •
1 . A to Z
2 . A = .234-inch diameter
3 . 2 = .413-inch diameter
5. Angles : (See Figure 10 .7 .)

A . For mild steel :
1 . Lip angle is 59 degrees .
B . For bard steel :
1 . lip angle is 65 degrees .
6 . Common drill troubles and causes . ( See Figure 10 .8 . )
7 . Suggested speeds and feeds for high speed drills . (Refer to Figure 10 .10
through 10 .12 . )
8 . Cutting fluids . (Refer to work order or to Figure 10 . 13 where cutting fluids

are not prohibited . )
9 . Drilling Tips :
A . Material should always be center punched to aid in accurately starting drill
B . To s oid breaking drill , ease up on feed preeeure as drill starts to break

through .
C . Material to be drilled should always be clamped to drill press table to

prevent material from spinning if drill seizes .
•
lU-8

BNA08758725
H DMSp01659650
HAND TOOLS
•
Drilling Tips : (Continued )
D . Hand held drills 3/8" and larger should always be used with extra side grip
to avoid having drill motor wrenched from the hand if the drill seizes .
E . A drill is not a satisfactory tool for making large holes in sheet metal .
Fly cutters, chassis punches or special thin metal hole cutter should be
used .
F . Remember that drilling, especially hand held drills do not produce accurate
holes either in regard to location or hole diameter . Accurate diameter
holes (to within a thousandth) are usually produced by drilling with a drill
1/64-inch undersize and finishing with a reamer to size .
CUTTING EDGE OR LI P
LIP CLEARANC E
DEAD CENTE R
CUTTING EDGE OR LI P
•
Figure 10 . 6 Parts of a Dril l
Lip clearance--Lip clearance is the relief which is given the cutting edges of the
drill to allow them to cater the metal without interference , The heel is ground
away from the cutting lip at an angle of 12 to 18 degrees for drills pointed for
aluminum and 10 to 14 degrees for drills to be used on stainless steel and titanium .
POINTING POINT NOTCHING
Length and Angle of the Lips--The lips are of equal length and at the same angle
with the axis of the drill .
• Figure 10 .7 Drill Angles (Sheet 1 of 2)
10-9

BNA08758726
H DMSp01659651
MECHANIC IS RiNDBOOK
FOR STAINLESS STEEL FOR ALUMINU M

AND TITANIUM
Central Locations of Point and Center of the Drill--If 1 and 2 have been correctly
ground, the point and dead center will be centrally located on the axis of the drill .
Figure 10 .7 Drill Aaglaa (Shoot 2 of 2 )
10-10

BNA0875872 7
H DMSp01659652
•
•
EXCESSIVE INSUFFICIENT
LIP CLEARANC E LIP CLEARANC E
USING DRILL WITHOUT

CHIP BREAKER TO CUT
BRASS OR COPPE R
FORCING DRILL LIPS OF

INTO WOR K UNEQUAL LENGT H
(EXCESSIVE FEED) AND ANGLE
Figure 10 .8 Common Drill Troubles end Causes

DDCILINIC' S HAA'D000E
TAP DECIMAL
DRILL SIZE S EQUIVALENTS
~u ~MUUCe
Figure 10 . 9 Drill Sizes
10-12

BNA0875872 9
H DMSp01659654
HAND TOOLS
Recommended Recommende d
• Spee d Spee d
Material SFPM Material SFFM
Alcminum and its Alloys . 200-300 Slate, Marble , Stone . . . . 15-2 5

Bakelite . . . . . . . . 100-150 Steel Forgimgs . . . . . . . 50-6 0
Brass , Bronze (Soft ) . . . 200-300 Steel , Manganese (15 . . 15-2 5

per cent Mn )
Bronze (High Tensile) 70-100
100-150 Steel ( Soft ) . . . . . . . . 80-11 0
Cast Iron ( Soft ) . . . . .
Stainless Steel . . . . . . . 30-4 0
Cast Iron ( Hard ) . . 70-100
Tool Steel . . . . . . . . . 50-6 0
Magnesium and its Alloys . 250-400
Wrought Iron . . . . . . . . 50-6 0
Malleable Iron . . . . . . 80-90
Nickel and Monel Metal . . 40-60 Wood . . . . . . . . . . . . 300-400
Carbon steel drills should be run at speeds approximately 40 to 50 per cent of

those recommended for high speed drills .
Figure 10 .10 Suggested Speeds for High Speed Drill s
Feed Fee d
Drill per Drill pe r
•
Diameter Revolution Diameter Revolution
Inches Inches Inches Inche s
Under 1/8 .001 to .002 1/2 to 1 .007 to .01 5

1/8 to 1/4 .002 to . 004 1 Inch and Over . 015 to .025
1/4 to 1/2 .004 to .007 . . . . . . . . . . . . . . .
Note : It is best to start with a moderate speed and feed , increasing either
one, or both , after observing the action and condition of the drill .
Figure 10 . 11 Feeds for Drill s
•
10-1 3

BNA0875873 0
H DMSp01659655
Size Surface Feet Per Minut e
Decimal 10 15 20 25 30 40 50 60 70 80 90
Frao ti ana l Equivalent
Revolution. Per Minute
1/6h .015625 2448 3672 4890 6112 7334 9779 12224 14669 17114 19558 22003
1/32 .03125 1222 1834 2445 3056 3667 4890 6112 7334 8557 9779 11002
1/16 .0625 611 917 1222 1528 1834 2445 3056 3667 4278 4890 550 1
3/32 .09375 407 611 815 1019 1222 1630 2037 2445 2852 3260 3667
1/8 .125 305 458 611 764 917 1222 1528 2139 2445
1834 2750
5/32 .15625 244 367 489 611 733 978 1222 1467 1711 1956 2200
3/16 .1875 204 306 1,07 509 611 815 1019 1222 1426 1630 1831,
7/32 .21875 175 262 349 437 524 699 873 1048 1222 1397 1572
1/4 .250 153 229 306 382 458 611 764 917 1070 1222 1375
5/16 .3125 122 183 244 306 367 489 611 733 1100
056 978
3/8 .375 102 153 204 255 306 407 509 611 713 815 91 7
7/16 .4375 87 131 175 218 262 349 431 521, 611 699 786
1/2 .500 76 115 153 191 229 306 392 458 535 611 668
9/16 .5625 68 102 136 170 204 272 340 407 475 543 61 1
5/8 .625 61 92 122 153 183 244 306 367 428 489 55 0
11/16 .6875 56 83 111 139 167 222 278 333 389 445 500
3/4 .750 51 76 102 127 153 204 255 306 357 407 45 8
13/16 .8125 47 70 91. 118 141 188 235 282 329 376 42 3
71/8 .875 44 65 87 109 131 175 218 262 306 31,9 39 3
15/16 .9375 41 61 81 102 122 163 204 244 285 326 36 7
1 1 .000 38 57 76 96 115 152 191 229 267 305 34 4
Figure 10 . 12 Operating Speeds--Fractional Sizes (Sheet 1 of 4)
0 0 0
0
Size Surface Feet Per Minut e
Decimal 100 125 150 175 200 250 300 400 600 1000
Fractional Equivalent
Revolutions Per Minut e
1 64 .015625 24448 30528 3667 2
1/32 .03125 12224 15364 18336

1/16 .0625 6112 7632 9168 10688 12024
3/32 .09375 4075 5088 6112 7125 8149 10187

1/8 .125 3056 3816 4584 5344 61l2 7640 9168 12224
5/32 .15625 2445 3053 3667 4275 4890 6112 7334 9779 1466 9
3/16 .1875 2037 2544 3056 3563 4075 5093 6112 8149 1222 4
7/32 .21875 1746 2181 2619 3054 3493 4366 5239 6985 1047 0
1/4 .250 1528 1908 2292 2672 3056 3820 4584 6112 9168 1527 6
5/16 .3125 1222 1526 1834 2138 241,5 3056 3667 4890 7334 1222 1
3/8 .375 1019 1272 1528 1781 2037 2547 3056 4075 , 6412 1018 4
7/16 .4375 B73 1090 1380 1527 1746 2183 2619 3493 5239 872 9
1/2 .500 764 954 1146 1336 1528 1910 2292 3056 4584 763 8
9/16 .5625 679 848 1019 1188 1358 1698 2037 2716 4075 678 9
5/8 .625 611 763 917 1069 1202 1528 1834 2445 3667 611 0
11/16 .6875 556 694 833 972 1111 1389 1667 2223 3334 555 5
3/4 .750 509 636 764 891 1019 1273 1528 2037 3056 509 2
13/16 .8125 470 587 705 822 940 1175 1410 1881 2821 470 0
7/8 .675 437 545 655 763 873 1091 1310 1746 2619 436 5
15/16 .9375 407 509 611 713 815 1019 1222 1630 2445 407 4
1 1 .000 382 477 573 668 764 955 1146 1528 2292 3820
O
Figure 10 .12 Operating Speeds--Fractional Sizes ( Sheet 2 of 4)
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10-1 6

BNA0875873 3
H DMSp01659658
HAND TOOLS
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•
10-1 7

BNA08758734
H DMSp01659659
Aluminum an d its alloys : Soluble oil ; kerosene and lard oil compounds ;
light, non- viscous, neutral oil ; kerosen e
and soluble oil mixtures .
Brass : Dry ; soluble oil ; kerosene and lard oil com -

pounds ; light , non-viscous , neutral oil .
Copper : Soluble oil ; winter - strained lard oil ; olei c

acid compounds .
Cast Iron : Dry, or with a jet of compressed air for a

cooling medium .
Malleable Iron : Soluble oil, or non -viscous , neutral oil .
Monel Metal : Soluble oil , or sulfurized mineral oil .
Steel, Ordinary : Soluble oil ; sulfurized oil ; high

Extreme Pressure value mineral oil .
Steel , very hard and Soluble oil , or sulfurized minera l

refracto ry : oil .
Steel, Stainless Soluble oil, or sulfurized mineral oil .
Wrought Iron : Soluble oil ; sulfurized oil ; high animal

oil content , mineral oil compound .
•
Intermittent cooling of hardened steel should be avoided , as it may caus e
small checks or cracks which will result in tool failure .
Figure 10 . 13 Recommended Cutting Fluids
10-1 e
CONFIDENTIAL LEVELS - UNDER PROTECTIVE ORDER ,

BNA0875873 5
H DMSp01659660
HAND TOOLS
•
MICROMETERS
The micrometer is the most commonly used precision tool in use . It is used far
accurately measuring dimensions . A micrometer divides the inch into 1000 parts .
It has a screw with 40 threads per inch which advances through a nut at .025 of
an inch per revolution . (See Figure 10 .16 for typical readings . )
CARE AND USE

1 . Slowly bring the micrometer measuring surfaces together using a light pressure .
Avoid plac _ng micrometer where it might be affected by heat . A micrometer is a
precision tool ; mistreatment by dropping it on the floor , or flooding it with
coolant containing eme ry may impair its accuracy . Protect the micrometer when
not in use by storing it away from grit and dirt .
RATCHET STOP AND CLAMP RIND

1 . The ratchet stop provides a uniform measuring pressure of approximately 1 pound,
4 ounces . A slight rotation of the outer ring of the clamp ring locks the
micrometer spindle at any desired setting .
2 . Never tighten clamp ring when spindle is removed . To do so may damage the
clamping mechanism .
TYPES
1 . Inside micrometer
2 . Outside micrometer
3• Depth micrometer
•
PRINCIPAL PARTS OF A MICROMETER (Figure 10 .15)
1 . Frame
2 . Anvil
3 Spindle
4 . Barrel
5 . Thimbl e
TOOLS USED IN CONJUNCTION WITH MICROMETER (Figure 10 .14)
1 . Ball gauge ( inside diameter 1/2 inch or less )

2 . "T' gauge or snap gauge ( inside diameter 1/2 inch or more )
O'LOER GAUGES
1 . Radius gauges ------Used to find radius of bend on parts you are copying .
2 . Thread gauges-------Used to get thread count on a bolt, in a hole, etc .

3 . Feeler gauges-------Used to check clearance between moving parts .
4 . Trammel points------Used in direct transfer of dimensions from parts,

blueprints, etc .
LO-1 9

BNA08758736
H DMSp01659661
INSIDE MEASUREMENT S
MEASURING DIAMETERS SHOWING THE ADVANTAGE OF

MEASURING IN A SLOT
THE CUT OUT FRAM E
Figure 10 .14 Uses tsr Miurusetor Calipe r
•
4th . . 32nd . .
I .2 5 I .0312
3 .75 3 .0937
8th .. 5 .1562
I .12 5 7 .2187
3 .375 9 .281 2
3 .625 I I .343 7
7 .67 5 13 .4062 A-ANVIL I-ADJUSTING NUT FOR
6 the . 15 .4687 B-SPINDLE THREAD WEA R
1 . .062 5 17 .531 2
19 .5937 C-CLAMP RING J-THIMBLE SLEEVE
35 131 2 5
7 .4375
21 .656 2
23 7187 D-F RAM E K-LOCK NUT FOR THIMBLE
9 .5625 25 .7812 E-BARREL SLEEVE AND MEASURING
II 667 5 27 643 7
13 .6125 29 .9062 F-THIMBLE SCRE W
15 .9375 31 .9687 6-MEASURING SCREW L-THIMBLE CAP
H-FIXED NUT WIT H M-RATCHET STOP
TAPERED EN D
Figure 10 .15 Micrometer Caliper Section View

NECHA.NIC'S HANDB001 :
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BNA08758739
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HAND TOOLS
•
VERNIER CALIPER
Direct readings of both outside and inside measurements can be obtained on Vernier
Calipers . The front side is graduated for outside measurements and the reverse
side for inside measurements . ( See Figure 10 .17 . )
The bar of the tool is graduated in twentieths of an inch ( .050 inch) . Every second
division represents a tenth of an inch and is numbered . On the Vernier plate there
is as space divided into 50 parts and numbered 0, 5, 10, 15, 20, 25, etc, to 50 . The
fifty divisions on the Vernier occupy the same space as 49 divisions on the bar .
To read the tool, note hoe many inches, tenths (or .100) and twentieths (or .050)
the 0 mark on the Vernier is from the 0 mark on the bar . Then note the number of
divisions en the Vernier from 0 to a line which exactly coincides with a line on
the bar .
Erample :
In the figure below the Vernier has been moved to the right one and four hundred
fifty thousandths (1 .450), as shown on tho bar and the fourteenth line on the
vernier coincides with a line, as indicated by the stars, on the bar . Fourteen
thousandths of an inch arc therefore to be added to the reading on the bar and the
total reading is one and four hundred and sixty-four thousandths inches (1 .464) .
Caution :
It is important for the bar to be wiped before moving the slide so that all dirt or
other particles are removed, thereby preventing possible damage to graduations and
interference with operation of the tool .
HOW TO READ A SO-DIVISIOEJ

VERNIER CALIPER DR HEIGHT GAGE
aL
Figure 10 .17 Vernier Caliper
10-2 3
CONFIDF.NTIA1 . 1,FXF.1, 1- i 7N )F.I0 PROTF.CTTVF. 012i)F.I0 ,

BNA0875874 0
H DMSp01659665
MECHANICS INNDBOO%
ofliC il GRINDFRS
•
Bench grinders are used by the mechanic for hand grinding operations , such as sharp-
ening chisels o s drivers , grinding drills, removing excess metal from work ,
etc . They are usually fitted with both a medium grain and a fine grain abrasive
wheel . In so cases v,ire brush wheel i substituted for one of the abrasive
wheels . The medium wheel is satisfactory for rough grinding . For grinding to close
huts for size , eharpeniug tools, or when a smooth finish is desired , the fine
wheel should be used .
DO'S AND DON' TS
1 . Never use soft materials on a grinder .

2 . Make sure tool rest is close to grinder wheel fl/8 inch or less) (Figure 10 .18) .
3 . Do not wear gloves or loose clothing when operating grinder .
4 . Never grind en the side of a wheel .
5 . Never jam the work into the face of the wheel .

6 . Never use a wheel that has a chunk out of it or a crack in it .
7 . Replace the wheel when it gets too small . (80 percent of its original diameter
or when ftcu 2 above is unattainable . )
8 . Make sure eye shield is in place . (Figure 10 .18)

9 . Always wear safety glasses .
10 . If wheel needs dressing use proper tool .

11 . Allow grinder wheel to get up to full rpm before using .
Figure 10 .18 Bench Grinder

•
10-24

BNA0875874 1
H DMSp01659666
HAND TOOL S
HOLDING DEVICE S
Vises and clamps are tools used for holding work of various kinds on which some
operation is being performed .
CLASSIFICATIONS
1 . Machinist vise
2 . Utility bench vise ( most common )
3 . Drill press vise ( usually has to be clamped to drill press table)
4 . " C" clamps ( come in many sizes )

5 . Parallel clamps
6 . Pipe vis e
Note : On bench vises soft jaws are sometimes needed to protect part . (See
figure 10 .19)
PUNCHES AMID PUNCHING
Punches ore used to locate centers for drawing circles, to start hole for drilling,
to punch holes in metal sheets , and to drive out pins or bolts . ( See figure 10 .19 1
CLASSIFICATIONS
• Prick punch-------------Used to mark center .
Center punch------------ Used to mark drill point center .

Pin punch--------------- Indicates pin diameter , stock diameter .
Storting punch----------Used to drive out bolts , pins, etc_
Scribes -----------------Used to scribe lines on metal , not used on aluminum .

Aligning punch----------Used to align flange holes .
CHISELS
Chisels are tools used to cut , chip, or remove metal . They are made of good grade
tool steel , hardened at the point and sharpened to a cutting edge . They will cut
any metal softer than themselves . Never use a chisel with a mushroomed head . See
figure 10 . 20 for "before" and "after" dressing .
CLASSIFICATIONS
1 . Plat --------------------Used for cutting sheet metal or for chipping .

2 . Cape--------------------Used for cutting grooves, slots or keyways .
3 . Hound nose -------------- Used for cutting round ( concave ) grooves .
4 . Diamond point-------- ---Used for cutting V shaped grooves .
10-2 5

BNA08758742
H DMSp01659667
14ECSANIC' S H41DD0CK
PIN PUNCH
DRIFT PUNC H
CENTER PUNCH
ALIGNING PUNC H
WITHOUT 71 CENTER
CENTER PUNC H
PUNCH MAR K
MARK KEEP S
THE
DRILL
FROM
WANDERIN G
TO DRIVE OUT
A PIN OR BOL T
PUNCH MARKS MAKE IT EASY
TO RE-ASSEMBLE TWO PARTS
IN THEIR ORIGINAL POSITIO N
CENTER PUNCH POINT
Device and Pouche s

Figure 10 .19 holding
•
10-2 6
CONFIDENTIAL LEVEL I - UNDER PROTECTIV E ORDER,

BNA0875874 3
H D M Sp01659668
HAND TOOLS
COLD CHISEL
CAPE CHISEL ROUND NOSE CHISEL
DIAMOND POINT CHISEL
BEFORE AND AFTER DRESSING
TO CUT OFF A LARGE RIVET HEAD, FIRST CUT GROOVE

THROUGH CENTER OF RIVET HEAD WITH CAPE CHISEL AS
SHOWN IN ~A' THEN CUT OFF HEAD WITH FLAT CHISEL
AS SHOWN IN B .
Figure 10 .20 Chisel s
•
10-2 7

BNA0875874 4
H DMSp01659669
MECHANIC'S HANDBOOK
•
HAMMERS
Hammers a classified as cmmon , soft and sledges . Each has its special u The
followingr information will aid in selecting the right hammer for the particular work
at hoed . (See figure 10 .21 )
CLASSIFICATION S
1 . The common ( ball-peen ) hammer is used for sheet metal work, driving rivets,
general purpose work, and the peen does a good job of cutting out holes for
cap screws or studs .
2 . The soft hampers have heads made of lead , copper and babbit . These hammers
used when force i needed but you do not want to damage the part bein g
struck . Frequent dressing of the head is necessary due to the mushrooming
effect from hard usageSoft hammers a also made o t of plastic and raw-
hide . These should be used on parts where damage to part cannot be toler-
ated .
3. Sledges are used for heavy work, where great force is needed , such as : slug
wrench applications, driving stakes or breaking up rock . ( See figure 10 .27 )
Note : Hammer handles should always fit head tightly . Do not use the end of the
hammer handle for bumping purposes , this will split and ruin the handle .
Never use the handle for prying .
10-2 8
•

BNA0875874 5
H DMSp01659670
BAND TOOL S
BALL PEE N
•
FACE
PLASTIC HAMMER
BRASS HAMMER
Figure 10 .21 Harmers
10-2 9

BNA08758746
H DMSp01659671
SHEARS AND PLIERS
Shears, pliers and nippers are tools used to hold, turn , cut, shape or bend light
work by hand . (See Figure 10 .22 )
PLIERS
A. Slip joint (5" to 10")

B. Duck bil l
C. Needle nos e
D. Water pump ( channel type)
E. Vise clamp
SHEARS
A . Right and left cutting snips

B . Tin snip s
C . Dikes (diagonal cutters )
1 . Shears are used for cutting sheet metal of various materials and thickness .
2 . Pliers are used principally for bolding or beading thin material, or cutting
electrical wire .
3 . Diagonal cutters are used for cutting off small stock, such as cotter keys and
electrical wire .
4 . Avoid using pliers on a hardened surface as this dulls the teeth and will cause
loss of grip .
•
5 . Lang nose pliers often help a mechanic out of a tight spot in recovering a washer
or a nut which gets into a hard-to-reach spot, and in safety wiring applications
where the wire has to be pushed or pulled through a hole .
6 . Mechanics sometimes use pliers for loosening or tightening nuts . Always use
wrenches on nuts, NEVER PLIERS . In fact , don't use pliers when any other tool
will work .
7 . Pliers like all other tools , should be kept clean .
THE SLIP JOINT PERMITS JAWS

TO BE OPENED WIDER
DUCKBILL PLIERS
DON'T USE PLIERS ON NUTS
Figure 10 .22 Pliers
10-3 0

BNA08758747
H DMSp01659672
HAND TOOLS
SCE WDEIVEES
A screwdriver is intended for one principal purpose----- to loosen or tighten screws .
COMMON ( General Purpose ) (Figure 10 .23 )
1 . Screwdrivers for general purpose are classified by size according to the length
of the shank and blade - Various sizes are : 2-1/2, 3, 4, 5, 6 , 8, 10, and 12
inches . The blade tip is proportionate to the length of the shank and blade .
A . Select the right size screwdriver for the screw slot . This not only pre-
vents the screw slot from becoming burred and the blade tip from being
damaged , but reduces the force required to keep the screwdriver in the slot .
B . Screwdrivers are not designed to be used as a pry or pinch bar , and if muc h
force is applied when so used, it might bend or the blade may break . The
tip of the blade is hardened to keep it from wearing , and the harder it is
the easier it will break if a heavy beading strain is applied .
C . Don't hammer on the end of a screwdriver . It is not to be used in place of
a cold chisel , a punch , or a drift punch .
If one has to remove a rusty screw and the slot is full of rust ; tap gently
on the handle of the screwdriver , holding it at an angle to the slot of the
screw . After the slot is cleared sufficiently one can tap on the screw-
driver with a hammer to seat it well into the slot before t ry ing to loosen
the screw .
D . Don't use pliers on a screwdriver .
• E . If a screwdriver blade becomes damaged through misuse it can be made serv-

iceable again by grinding it on an emery wheel .
1 . First grind the tip straight and at a right angle to the shank .
Note : Never bold the screwdriver against the eme ry wheel more than
several seconds at a time . Keep dipping the blade in water to
keep it cool .
2 . After the tip is ground square , dress off a little at a time from each
face . Be careful to keep the blade thick enough to make a fairly tight
fit in the slot of the screw for which the screwdriver is intended .
3 . Keep the faces parallel for a short distance or have them taper in a
slight amount . Never gr ind the faces so they taper to a sharp edge at
the tip . ( See figure 10 .23 )
•
10-31

BNA0875874 8
H DMSp01659673
MECHANIC'S HANDBOO K
PHILLIPS
The tips of these screwdrivers have two points which c s at the cen ter . These
points correspond to the slots in the head of the screw . s The correct size screw-
driver most be used for each different size screw . The sizes most commonly used
at the Field Laboratories are : No . 1, No . 2, and No . 3 .
The advantage of Phillips head screws over screws with standard slots is that the
screwdriver can't slide sideways outs of the slot and mar a surface . However, more
downward pressure must be exerted an the Phillips screwdriver to keep it in the
cross-slot .
REED AND PRINC E

Another type of recessed head screw in common use is the Reed and Prince cross-slot
screw . This type of screw should not be confused with the Phillips screw for there
is a great difference in the slots . Compare them closely and you will see that each
requires a special and different type of screwdriver . The sizes most commonly seen
are : 1/4", 3/16", 5/16", and 3/8" .
OFFSET
The offset screwdriver has one blade forged in line with the shank or handle and the
other blade at right angles to the shank . With such a arrangement, when the swing-
ing space for the screwdriver is limited , the mechanic can change ends after each
swing and thus work the screw in or out of the threaded hole . The tips of the blade
can be either Comm on or Phillips or a combination of both .
is
8-A POOR FIT

DAMAGES SCREW
DRIVER AND
SCREW SLOT
GROUND U f GROUND
A - SHOWS HOW LT RIGHT WRONG
A SCREWDRIVER
SHOULD FIT THE
SCREW SLOT
REED 9 PRINCE
E
OFFSET SCREWDRIVER L
MR
PHILLIPS HEAD SCREW AND SCREWDRIVE R
Figure 10 .23 Screwdriver s
10-32

BNA08758749
H DMSp01659674
MIND TOOL S
WRENCHES
ORE-END WRENCHES
1 . Solid non -adjustable wrenches with openings in each end are called open-end
wrenches . The average set in a tool kit numbers about 10 wrenches with openings
that range from 5/16 to 1 inch . This combination of size . will fit most of the
nuts , cap-screws and bolts normally used . ( Figure 10 .24 . )
2 . The size of the openings between the jaws determines the size of the wrench .
The openings actually measure from five to fifteen thousandths of an inch larger
than the nominal sizes marked on the wrenches , no that they can easily be slip-
ped onto the nuts or bolt heads .
3 . The smaller the openings in the wreath , the shorter its overall length . The
larger the opening the longer its overall length . This proportions the lever
advantage of the wrench to the size of the bolt or nut . This helps reduce the
possibility of the mechanic applying too great a force on the bolt or nut .
4 . It takes practice to know whether you are using enough or too much force on a
wrench . Experience develops a sense of "feel" which enables a mechanic to know
whether a not or cap- screw is tightened the right amount .
5 . There are a few simple rules for the correct use of open -end wrenches :
A . Be sure that the wrench fits the nut or bolt head .
B . When one has to put a hard pull on a wrench , make sure the wrench seats
squarely on the sides of the nut .
C . Always PULL on a wrench----don't PUSH . If one pushes on a wrench and the
nut breaks loose, you will invariably strike your knuckles . ( Figure 10 .24 .)
• D . If one most push on the wrench , use the base of the palm and-hold your hand
open . This will avoid injury to your knuckles .
E . When the jaws on an open- end wrench become spread , replace the wrench .
F . Do not use a cheater ( extension) on a wrench .
10-33

BNA0875875 0
H DMSp01659675
0 i~ () (t))
GOOD FIT
0
BAD FIT
PULLING ON A WRENCH IS SAFE R
Figure 10 .24 Open End Wrenche s
10-34

BNA0875875 1
H DMSp01659676
NAND TOOL S
•
BOX WRENCHES
1 . Box wrenches are ve ry popular with mechanics . One reason for this is that they
can be operated in ve ry close quarters . They are called " box" wrenches because
they box or completely surround the at or bolt bead . (Figure 10 .25_ )
2 . Box wrenches commonly are either 6 point of 12 point . A 12 point wrench can be
used to continuously loosen or tighten a out with a minimum swing of the handle .
3 . Still another advantage of the box wrench is that there is practically no chance
of the wrench slipping off the nut and it can't spread on the nut .
4 . The sides of the opening in a box wrench are thin and it is ideally suited for
nuts which are hard to get at with an open-end wrench .
5 . Some, box wrenches have the heads set at an angle of 15 degrees to the handle .
This tips the end of the wrench which is not on the nut upward and provides
clearance for the mechanic ' s hand .
6 . The same rules for use shown for open-end wrenches hold true for box wrenches .
BOX WRENCH
USING
Box
WRENCH
Figure 10 . 25 Box Wrenche s
COMBINATION BOX AND OPEN-END WRENC H

1 . Many mechanics prefer combination wrenches . A box wrench on one end and an
open-end wrench on the other . They use the box end for " breaking-loose : or
"snugging down" nuts and use the open-end the rest of the time . (Figure 10 .26 . )
COMBINATION BOX AND OPEN-END
Figure 10 . 26 Combination Box and Open-Seed Wrenc h
•
10-35

BNA08758752
H DMSp01659677
MECHANIC'S HANDBOOK
STRIKING WRENCH
1 . You never should liaomer on a wrench, but there is one exception . There is a
type of box wrench made for this purpose . These wrenches are heavy and strongly
made . The handle is short and has a pad on which the hammer blows are struck .
These box wrenches are known as "slugging" or "striking" wrenches . These
wrenches are especially useful on large size nuts .
THIS WRENCH IS DESIGNED TO RE

STRUCH WITH A SLEDGE HAMME R •
Figure 10 .27 Sledging Wrench
SET-SCREW WRENCHE S
1 . The trade name for this type is an Allen wrench . All of them are L-shaped bars
o f tool steel . The most common type is hexagonal to fit the hexagon socket i n
the set screw .
2. These set screw wrenches wary in size according to the size of the socket in the
set screw . These wrenches usually come in a set when they are purchased . The
erect size must be used or the screw socket will be rounded out and next to
impossible to remove .
ALLEN WRENCH
SET SCREW
Figure 10 .28 Set-Screw Wrenc h
10-3 6

BNA0875875 3
H DMSp01659678
WD TOOLS
SOCKET WRENCHES
1 . The type of wrench which has done most to moke the mechanics work easier and
save time is the socket wrench .
2 . The socket is detachable and may be attached to so-cal different types of
handles for many different applications . ( See figures 10 .29, 30 , 31, 32, and 33)
3 . The handle most commonly used is the ratchet . ( Figure 10 .29 . )
4 . Socket wrench sets also contain extra deep sockets for use on nuts which are a
long way down on the bolt , or for bolts that are in recessed holes . (Figure
10 .30 . )
4r~4t TlNO
Figure 10 . 29 Ratchet Handl e
EARLY TYPE MODERN

6-POINT SOCKET 12-POINT SOCKET DEEP SOCKETS
Figure 10 . 30 Ratchet Handle and Deep Sockets
0
10-3 7

BNA0875875 4
H DMSp01659679
HINGED OFFSET HANDLE

1. The hinged offset handle i very convenient . To loosen a tight nut the handle •
can be swung so as to be at a right angle to the socket and thus provide the
greatest possible leverage . Then , after the nut is loosened to the point where
it turns easily , the handle can be hinged into the vertical position and twisted
by the fingers to completely remove the nut from the bolt or stud . ( Figure
10 .31 .)
WSIGNET ENO OF
HINGED OFFSET HANDL E
S ING AT RIGHT
ANGLE FOR GREATEST
LEVERAGE
Figure 10 .31 Hinged Offset Handl e
SLIDING OFFSET HANDLE
1 . The head can be positioned at the end or at the center of the handle . The slid-
ing offset and an extension bar can be made up as a "T" handle . ( Figure 10 .32 . )
0
i'
SLIDING OFFSET HANDLE
Figure 10 .32 Sliding Offset Handl e
SPEED HANDLE
1 . Speed handles sometimes called "speeders" or "spinners " are convenient for many
jobs . The speed handle is worked like a brace which the woodworker uses with a
bit to bore holes . A speed wrench will help you get nuts off in a hurry after
they are first broken loose . (Figure 10 .33 . )
SPEED HANDLE
Figure 10 . 33 Speed Handl e
•
10-38

BNA0875875 5
H DMSp01659680
HAND TOOLS
•
ADJUSTABLE WRENCHES ( Not to be used unless approved by supervvisor . )
1 . Adjustable wrenches are shaped somewhat similar to open-end wrenches but have
one jaw adjustable . (Figure 10 .34 . )
2 . The eagle of the opening to the handle on an adjustable wrench is 22-1/2

degrees .
3 . Although adjustable wrenches are convenient , they are not intended to take the
place of standard open-end wrenches , box wrenches , or socket wrenches .
4 . Adjustable wrenches aren't intended for hard se rv ice , treat them gently .
5 . There are two important rules to remember :
A . Always place the wrench on the nut so that the pulling force is applied to
the stationary jaw side of the handle . (Figure 10 .34 . )
B . After placing the wrench on the nut , tighten the adjusting knurl so that the
wrench fits the nut snugly . (Figure 10 .34 . )
6 . Adjustable wrenches , like all other tools , should be kept clean . Give them a
bath in cleaning solvent and apply a little light oil to the knurl and the sides
of the adjustable jaw where it slides in the body .
7 . Inspect them for cracked knurls or jaws which may result in failures .
BAD PRACTICE
DON'T PULL ON AN
ADJUSTABLE WRENCH
UNTIL IT HAS BEEN
TIGHTENED ON THE NU T
Figure 10 .34 Adjustable Wrenc h

PIPE WRENCHES
1 . There is need on occasions for using a pipe wrench, but only on round objects,
never on hexagon or square nuts . The teeth on the jaws of the pipe wrench
always leave their mark on the work . No instructions are necessary on which way
to pull on this wrench because it works only in one direction . However, the
wrench works best when the "bite" is taken at about the center of the jaws .
(Figure 10 .35- )
• Figure 10 . 35 Pipe wrencia
10-39

BNA08758756
H DMSp01659681
1ECHANIC - S HANDBOO K
TII1IEADS, TAPS AND DILS
GINLNAL INFOIZNTION
1 . In a embly and disassembly operations in test areas, threaded parts such as

nuts, bolts and screws are Handled so frequently that every mechanic should be
thoroughly familiar ,,itl, the v s types and their uses, and should understand
the common methods of cutting or renewing threads .
Toro types of threads ""T"' Y used a , National Coarse (NC) and National Fine
(NP) . NC threads range Irom 6 to 64r threads per inch, NP from 12 to 80 per such .
3 . In cutting threads two measurements must be Known - the dsonic ter and piteb .
Machine screws have their diameter indicated by a number, No . 0 being the small-
est and No . 12 the largest, to this number is always added the number of threads
per inch as No . 10-24 . Larger sized screws or bolts have their diameters indi-
cated by actual measurement as 5,16-24 .
4 . Use of Taps :
A . Taps are tools used for cutting in side or female threads ii: holes i, metal .
fiber or other material . The top should always be cleaned before use .
B . There are three forms of taps :

1 . Taper tap----(always used first )
The taper tap is used to start all threads and may be used to finish
the operation when it can be run entirely through the work .
2 . Plug tap-----(2nd one used )

The plug tap is used when one end of the hole is closed .
3 . Bottoming tap----(last one used )

The bottoming tap is used when it is necessary to cut a full bread to
the bottom of a closed hole . Plug taps or bottoming taps should never
be used to start a thread . •
Note : Start all taps perpendicular to the hole .
5. Use of Dies :
Dies are used for cutting male or external threads .
A . Clean die before use .
B . Die adjustment screw started loosely and then adjusted tighter, in steps .
while making threads .
C . Die inserted in handle (stock) with tapered thread side down or towards
the work .
D . Set screw in handle inserted in recess hole in die and securely tightened .
E . Die started perpendicular to center line of part .
F . Use proper cutting fluid .
G . Bach: off die after every 1i'2 to I turn to remove chips .
•
10-4 0

BNA08758757
H DMSp01659682
HAND TOOLS
•
COMBINATION SQUIRE
L A combination square combines in handy form the equivalent of several tools ;

inside try square, outside try square, mitre square, plumb, level, depth gage,
marking gage, straight edge, etc .
2 . Blade is usually 12 inches long . The handle can be moved to any position on
the blade . The handle i usually fitted with one or twc level glasses, and
a scratch awl screwed into handle .
3- Graduations on the blade are in 8ths , 16ths, and 32nds . Handle can be locked
to the blade at any position by a knurled knob .
4 . Common uses for the combination square are shown in Figure 10 .37 .
PROTRACTOR
1 . Common uses for the protractor are shown in Figure 10 .36 .
GRADUATED BLADES
CHECKING ALIGNMENT
OF CYLINDER BORE WITH
V-EDGE BLADE
MEASURING
ANGLES
Figure 10 .36 Uses for Protractor
•
10-4 1
CONFIDENTIAL LEVEL I- UNDER PROTECTIVE ORDER,

BNA0875875 8
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MECHANIC'S HANDBOOK
a
F
•
10-42

BNA08758759
H DMSp01659684
HAND TOOLS
• TUBE CUTTERS
To provide a good tube joint the tube must be cut off square . This is best accom-
plished by the use of a tube cutter which is shown in Figure 10 .38 . Cut tubing as
follows :
Figure 10 .38 Tube Cutter
1 . Clamp standard tube cutter over tube .
2 . Rotate cutter towards . its open side , gradually feeding cutting wheel downward by
turning adjustable screw . Do not feed wheel too rapidly . The cutting wheel
should be fed only while the cutter is being rotated , as dente will be caused i
tubing when the wheel is fed while the cutter is not moving . Moderate or light
tension on the adjustable screw will maintain an even tension on the cutting
wheel . This prevents bending and avoids excessive burrs on soft tubing .
TUBE Bl'NDLRS
Tubing installations requiring bends must he accomplished with minimum distortion and
restriction of the tubing . Attempts at tube bending with improper tools or by in-
• correct methods will result in constricted sections of bend with a reduction of fluid
flow .
When correct equipment and methods are used , bends with little or no flattening are
produced . Common defects in bending are flattening , kinking , or wrinkling .
Flattened bends result from not having the mandrel far enough forward in the tube, by
bending thin -walled tubes without a mandrel, or when too short " a radius is attempted .
A kinked and flattened bend is caused by slipping of the tube in the bender . Tubes
must be firmly clamped by the clamp block to prevent slippage during the bending
process .
Wrinkled bends result when thin-walled tube is bent without a supporting mandrel .
When hard tubing is beat, breakage will sometimes occur when the mandrel is too far
forward in the tube or when too short a radius is attempted .
A typical hand tube bender is shown in Figure 10 .39 . A bench iustalled tube bende r
is shown in Figure 10 .40 .
0
Figure 10 .39 (band Tube Bender Figure 10 . 40 Bench Tube Bender
10-4 3

BNA0875876 0
H DMSp01659685
TUBE FLARING TOO L •

GRIP DIE
The flared-type grip die consists of two steel blocks placed side by side and held in
alignment by steel pilot pins pressed into one block end extending into corresponding
holes in the other block . A number of countersunk holes are drilled along the grip
die section of the tool, the holes varying in size to correspond with the tubing size .
The grip die is designed to grip the tubes tightly without damaging them . The flar-
ing tool for this die consists of a cylindrical bar tapered at one end to correspond
with the angles of countersunk holes . ( See Figure 10 .41 . )
Figure 10 .41 Grip Die Tube Flaring Too l
Procedures for flaring tubing are as follows : •
1 . Insert tube into correct diameter hole of flaring tool die and clamp block dies
tightly together . Allow tubing to extend upward through die approximately one-
half outside diameter of tube, secure assembly , place tapered end of flaring tool
into centerline of tubing , and tap lightly with hammer until walls of tube are
forced to assume shape of countersunk hole in die . Avoid cracking tube ends .
2 . Check flare by placing an AN819 sleeve over tube . The outside diameter of the
flare should extend approximately 1/16-inch beyond the end of the sleeve but
should not be longer than the largest outside diameter of the sleeve .
1U-44 •
CONFTDF,NTTAT . T,F,VF,T, T- ITNDF,R PROTF,CTTVF, ORDER ,

BNA0875876 1
Cdlifornia, No. C Y 97-1554
H DMSp01659686
HAND TOOL S
FLARING MACHINE
The flaring machine is designed for efficient production flaring of pressure tubing .
It co ists of an electric driven motor which drives a spindle inserted with a 37-
degree s flaring center tool or squaring and burring tool ; the rpm of this spindle is
regulated by the variable speed control rotor handle, and the horizontal movement of
the spindle is manually operated by a hand lever . The moving jaws which contain the
flaring dies will clamp and secure the tubing . The jaws are operated by a compressed
air actuator and controlled by a foot pedal air valve . It i s necessary to depress
the foot pedal air valve and move the operating lever to therigh(approximately one
mch) in order to close the movable jaws . ( See Figure 10 .42 . )
Figure 10 . 42 Tube Flaring Machin e
•
10-4 5

BNA08758762
H DMSp01659687
MECHANIC ' S 8611)B00K
Procedures for flaring tubing axe as follows :

•
1 . Install 37-degree flaring center into small tool adapter spindle .
2 Adjust calibrated ring on spindle for number which is tube OD , to align with
marked groove , by use of an Allen-type screwdriver .
3 . The die adapter is installed in the movable jaws and the matched flaring dies of
the correct tube OD size are placed in these adapters . All foreign matter in the
grooves of the jaws , adapter , and dies will be removed prior to assembly of these
parts .
4 . The tube stop finger on the fixed jaw should be allowed to drop to dead center of
the flaring die by means of the two - stage stops . The finger adjusting screw
should be turned to adjust the amount of tube length which sticks through the die
to determine the correct flare diameter .
5 . Slowly operate hand lever of horizontal spindle toward flaring die ; then adjust
and lock positive spindle stopscrew , located on top of machine casting , to keep
flaring center from coining tube and yet bringing tube flaring to correct diam-
eter .
6 . Start electric rooter by pushing switch to ON .
7 . Position tube into rear flare die and against finger stop .
S . Depress and hold foot pedal air valve and move operating lever slowly until mov-
able jaws close and clamp tube .
9 . Continue to use manual operating lever to flare tube until completed ; release it
and remove flared tube . •
10-4 6

BNA0875876 3
H DMSpO1659688
0
SECTION 11
MISCELLANEOU S
CONTENTS
Page
Compressed Gas Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 1
CDNFID ENTIAL LEN EL I - UNDER PROTECTIVE ORDER ,

BNA08758764
H DMSp01659689
BOTTLES
•
COMPRESSED GAS BOTTLE S
Compressed gas bottles o cylinders ar used to transport and store such gases a
nitrogen , helium, oxygen, acetylene, argon, hydrogen , carbon dioxide, fluorine, and
refrigerants at . pressures up to 3000 psi . Careful handling of these containers is
essential to prevent serious accidents from the high pressures or dangerous gases
involved . The following rules should be observed :
Storage
1 . Store in compatible areas . Store fuel and oxidizers in separate areas .
2 . Store upright and chained in position to prevent falling .
3 . Store at temperatures of less than 125 F, and preferably out of the direct sun-
light . In freezing weather keep valves dry.
4 . Store containers marked "NT " or "full" separately .
Transport
1 . Protective cap must be in place prior to movement .
2 . Handle carefully . Do not drop or bang together .
3 . Secure containers by chocks and chains or place on an approved rack .
4 . Keep acetylene bottles upright . (The contain liquid acetone in a porous filler .
The liquid may cause a fire if it gets into the regulator . )
• Use
1 . Open valves slowly and observe systems for leaks . If containers or cylinder
valves leak, do not attempt repair . Return the cylinder to the vendor, clearly
marking it as defective .
2 . Regulators and pressure gages provided for use with a particular gas most not be
used with other gases .
3 . Do not use a wrench to close valves equipped with hand wheels .
4 . Release the adjusting screw of the regulator before opening a cylinder valve ;
close the cylinder valve and release the pressure from the regulator before
removing it .
5 . Never lubricate bottle fittings . Lubricants can cause explosions upon contact
with oxidizers .
6 . Left-hand threads are indicated by a groove around the circumference of the nuts .
7 . Leave at least 25 psi in empty bottles to prevent contamination .
8 . Acetylene regulators must be net below 15 psi to avoid possible explosion .

9 . Compressed gas bottles require an I .C .C . inspection every 5 years . This date is
stamped on the neck of each bottle .
COMPRESSED GAS BOTTLES ARE

POTENTIALLY DANGEROUS --
TREAT THEM WITH RESPECT .
11- 1
CONFIDENTIAL LEVEL I- UNDER PROTECTIVE ORDER,

BNA0875876 5
H DMSp01659690
INDEX
Item Pag e
Abbreviations . 1-6
Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Adjustable Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39

lE Flared Tube Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1
-B-
Bench Grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Block and Tackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Box Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

Burst Diaphragms 4-2 1
-C-
Cable Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
•
Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Chisels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Combination Open-Ibsd Box Wrench . . . . . . . . . . . . . . . . . . . . . . . 10-35
Combination Square . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Compressed Gas Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Conical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Connections (see Pipe and lobe) . . . . . . . . . . . . . . . . . . . . . . . 3-1
Contraction and Expansion . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Conservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1
Fractions of an Inch . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Weights end Measures . . . . . . . . . . . . . . . . . . . . . . . . . 2- 3

BNA0875876 6
H DMSp01659691
1rroEx
(Continued)
Item Psge
Definitions
General .- . . . . . . . . . . . . . . . . . . . . . . . 1-6
Liquid Propellants . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Diffusico Pumps, Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
-F-
Edwards Field Laboratory Map . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Expansible Tube Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Expansion and Contraction of Pipe . . . . . . . . . . . . . . . . . . . . . . 3-20
Eye Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 7
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Applying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Bolts 5-4
Head Styles . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Screvs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Fire Control Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
First Aid Treatment Data . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-1
Flanged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-4
LenaBing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-8
Superpressure . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-5
Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3_11
Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 1
Flanges and Flanged Fittings . . . . . . . . . . . . . . . . . . . .` . . . . 3.4

Fork Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 3
-0-
Gate Valves . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 4-3

Gaskets and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Gasket Types and Materials . . . . . . . . . . . . . . . . . . . . . . . 6-4
ii •

BNA0875876 7
C1lifornia, No. CV 97-1554
H DMSp01659692
INDEX
(continued )
Item
Globe Valves 4-3

Good Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Good Practice Tips for Lubricants . . . . . . . . . . . . . . . . . . . . . . 6-9

Grayloc Flange Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 3_ 9
-H-
Hacksaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Hammers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Hoisting Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Hoisting Hooks . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . 8-if
Holding Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Hydrostatic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
_I_
Identification of Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

• Inclined Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Information Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
-J-
Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
-K-
Knot Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 9
Leak-Testing Vacuum Systems . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Lens-Ring Fitting . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 3-8

Liquid Propellants . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Compatible Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Fire Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Safety Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Load Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Lubricants and Seals . . 6-1

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
0-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
•
il l

BNA0875876 8
H DMSp01659693
INDEX
(contiauea )
Item Pag e
-M-
Manila Rope . . . 8-8

Material Compatibility . . . 7-9
Mechanical Pumps , Vacuum 3-38

Micrometers . 10-19
Mission of Field Laboratories 1-4
Nevada Field Laboratory Map . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Nuts . . . . . 5- 5
-0-
Chmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
C-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Pipe . . . . . . . . . . . . . . . . . . . . . 3- 1 •
l paneiom and Flexibility . . . . . . . . . . . . . . . . . . . . . . . 3-20
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Flanged Connections . . . . . . . . . . . . . . . . . . . . . . 3-9
Mammon Allowable Working Pressure . . . . . . . . . . . . . . . . . . . 3-1
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Support Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Threaded Connections . . . . . . . . . . . . . . . . . . . . . . . 3-5
Vacwm 3-36
Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Cleaning • . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Hydrostatic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Identifioatioa . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Symbols 2-4
Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Pipe Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
Pressurants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Pressure Regulators (see Regulators) . . . . . . . . . . . . . . . . . . . . . 4-25
Protractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Pull Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Punches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Pumps, Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
CONFIDENTIAL T,EVET, T - TINDER PROTECTIVE ORDER ,

BNA0875876 9
California, no. CV 97-1554
H DMSp01659694
DSDER
(Continued )
Item Page
-R-
Regulators - Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Grove Silty-Mite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Large Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Small Vohme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Belief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
RD Fitting Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
_8-
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safe Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Safety Clothing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Santa Susana Field Laboratory Map . . . . . . . . . . . . . . . . . . . . • • 1-1
• Screwdrivers
Screws
Seals . . . .
. .
. .
.
. .
. .
. .
. .
.
.
.
.
.
.
. .
. .
.
. .
. .
.
.
.
.
.
.
.
. . .
. . .
.
.
5_4
.
.
. .
. .
. .
. .
.
.
.
.
.
.
.
.
.
.
.
. 10-31
. 66
Set Screw Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Shackles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Shears and Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
Skids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Slings
Sling Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Socket Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7_5
Spiral Wound Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

. . . . . . . . . . . . . . . . . 3-9
Standard .1 Flanges . . . . . . . . . . .
Striking Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Superpressore Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Piping System . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

BNA0875877 0
H DMSp01659695
DIDER
(Continued )
Item Page
-T-
Taps and Dies to-40

Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Flanged Fittiaga . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Values . Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Values, Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 2
Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 0
Tubing 3-i
Bend Radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Flared Fitting s 3-5
Inatallation . . . . . . . . . . . . . . . . . . . . . . 3-20
Maximum Allowable Working Pressure . . . . . . . . . . . . . . . . . . . 3-6
RD Fitting Designation . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Superpressure Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Support Spacing 3-21
-V-
Vaeu s 3-36
. . . .
s
Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Piping Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Pressure Units . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
System Leak and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Valves . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 4-3
Bell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
.
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
.
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
.
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
.
Globe . . 4-3
Expansible Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Solenoid . . . . . . . . . . . . . . . . . . . . . . . 4- 8
Warmer Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . • 10-23

Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1
-W_
Waahera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Welding Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Wire Rope Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . • 10-39
Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
vi

BNA0875877 1
Califomia, No. CV 97-1554
H D M Sp01659696
INDEX
(Continued )
Item Pag e
Combination Open-End and Box . . . . . . . . . . . . . . . . . . . . . . 10-35

Open-End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10_39
Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Striking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36

BNAU8758772
H DMSp01659697

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PUBLICATION 513-P-2 REV 9.

A TECHNICAL TRAINING PUBLICATION

TNEROCKETDYNE TRAINING DEPARTMEN T

CONFID ENTIAL LEVEL I - UNDER PROTECTIVE ORDER,

CONFTDENTIA1, l,EV El, 1- t 1NDER PROTECTTVF. ORI)ER ,

Section 1 . GENERAL 1NFOQ tTION

Section 3 . . . . . . . . . . . . . . PIPE, PURE, AND FITTINGS

CONFIDENTIAL 1,TVP1, T - i7N1)T1i PROTPCTTVP ORDPT1 ,

GE LbL I1rFORM 3.TION

Map of Santa Susana Field Laboratory (SSFL) 1-1

Nap of Edwards Field Laboratory (FL) . . . . . . . . . . . . . . . . . . . . 1-2

Map of Nevada Field Laboratory (NFL) . . . . . . . . . . . . . . . . . . . . 1-3

Mission of Field Laboratoriea . . . . . . . . . . . . . . . . . . . . . . . . 1-i

Good Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Inforsation Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Abbreviations and Def iaitions in Use at

CONFIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

SANTA SUSANA FIELD LABORATOR Y

IT t~ "S'PARKIN I F GUARD HOUSE . MEAT

CONFIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

NEVADA FIELD LABORATOR Y

CONFIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

MISSION OF FIELD LABORATORIE S

1 . To perform all tests as schedule d

2 . Each test shall fulfill its predetermined objective s

I. . All operations shall be performed with safety and economy

Handling toxic or flammable materials, working around cryogenic or high-pressure sys-

Some jobs require specific items of protective clothing or equipment -- safety

CONFIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

INFORMATION 50 11S CES

To achieve required standardization , quality, and maximum safety, several documents

FIELD LABORATORIES MAMIAL (FLN)

This manual contains :

1 . Directives -- applicable to all field laboratorie s

• 2 . Index of safety oriented ROP's -- applicable to all field laboratorie s

3 . Field laboratory procedures -- applicable to a particular field laboratory

4 . Field laboratory manager 's bulletins -- applicable to a particular field

5 . Group and project instructions -- applicable to a particular test group . .

FIBINEFRING PROCESS SPECIFICATIONS

CONFIDENTIAL LEVEL I - UNDER PROTECTIVE ORDER ,

ABBREVIATIONS AND DEFINITIONS IN USE

Al . . . . . . . . . . . . . . Atomics International , Division of North American

AN . . . . . . . . . . . . . . Air Force-Navy aeronautical standard parts

AND . . . . . . . . . . . . . Air Force-Navy aeronautical design standard

ASME . . . . . . . . . . . . . American Society of Mechanical Engineers

ASTM . . . . . . . . . . . . . American Society for Testing Materials

CANO . . . . . . . . . . . . . Canoga Park Facility

C .C, C .H ., or R .C . . . . . . . Control Center , Control House, or Recording Center --

CTL . . . . . . . . . . . . . Components Teat Laboratory -- thoeo facilities where

CTF . . . . . . . . . . . . . Chlorine trifluoride

DETA Diethyleme triamine -- a rocket fuel additive

EAAT . . . . . . . . . . . . . Edward Air Force Base

ECS . . . . . . . . . . . . . Electrical Control Station - an installation

EFL . . . . . . . . . . . . . Edwards Field Laboratory -- the rocket test facility

CONFID ENTIAL LEVEL I - UNDER PROTECTIVE ORDER,

EL . . . . . . . . . . . . . . Equipment Laboratory -- a facility which cleans and