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Log No. CV-63-6130-78

SINGLE

LAUNCH VEHICLE FAMILIARIZATION MANUAL LITTLE JOE II


(TITLE UNCLASSIFIED)
* I III III

(HASArCB-82898) LAUUCB VEHICLE FAMILIARIZATION AH;OAC. LITTLE JOE 2

N75-76075) Dnclas 2977 7 _

,pAoES)

(General Dynamics/Convairyv 26 p

OCTOBER 1963

NASA CONTRACT NAS 9-492


NASA and NASA Contractors Omj

GIIIIIIIID
GENERAL. DYNAMICS COIMVAIR

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Log No. CV-63-6130-78

LAUNCH VEHICLE FAMILIARIZATION MANUAL LITTLE JOE II


(TITLE UNCLASSIFIED)

NASA CONTRACT NAS 9-492

SECURITY NOTICE THIS DOCUMER^ONTAINS INFORMATION AFFECTING THE NATIONAL^EFENSE OF TJ*F UNITED STATES WITHIN THE MEAN^G OF TbpJ? ESPIONAGE LAWS,; TITLE 18, U.S.C., SECTmjS ajgAND 794. ITS TRANSMISSION OR THE REVELffijgyN OF ITS CONTENTS IN

ANY MANNER TO AN UN^T HOBOED PERSON is PROHIBITED BY LAW.

IMUUBLE J<3 NASA HEADQUARTERS ONltfL

PREPARED BY TECHNICAL PUBLICATIONS

NASA and NASA Contractors Onljt

GIIIIIIIID
GENERAL DYIMAIVUCS I CONVAIR

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TABLE OF CONTENTS. SUBJECT . PAGE ill I 1

APPROVAL HISTORY OF LAUNCH VEHICLE FAMILIARIZATION MANUAL INTRODUCTION LAUNCH VEHICLE

Airf rame Fins Propulsion System Attitude Control System Command Destruct System Measurement System. Electrical System
LAUNCHER '.

1 k 6 6 6 6 6
7

Pivot Frame Azimuth Trucks Pivot Pin. Vehicle Support Platform Elevation Control Screw Jacks Mast GROUND SUPPORT EQUIPMENT TRANSPORTATION AND HANDLING LAUNCH VEHICLE PERFORMANCE SUPPORT MANUAL REFERENCE INDEX.

7 7 9 9 9 9 10 10 11 21 ,

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APPROVAL HISTORY OF LAUNCH VEHICLE FAMILIARIZATION MANUAL

1.

CS-63-003 submitted for approval "by ESN 7^9, dated 3 April 1963.

2. .CS-63-003 approved by -NASA letter, dated l6 April 1963, with recommendations. 3. CS-63-003, Revision A, dated 1^ October 1963 incorporates recommendations
and is submitted for information and retention.

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INTRODUCTION --

The National Aeronautics and Space Administration (NASA) Apollo manned lunar landing project has the ultimate objective of landing an exploratory team of men on the moon. These men vill conduct limited observation and exploration of the moon surface near their landing area, and then return to earth. Intermediate objectives of the project include scientific observation in the earthmoon space and lunar reconnaissance. The Spacecraft Modules used for this project vill be qualified in a series of major missions, proceeding from earth suborbital and orbital to circumlunar and ultimately to the lunar landing missions. Prior to missions using major launch vehicles, the Little Joe II Launch Vehicle, shown on Figure 1, will be used to qualify the unmanned Apollo Launch Escape System and Command Module at- conditions simulating abort at high dynamic pressure. This manual is an orientation-indoctrination type document containing a description of the Little Joe II launch vehicle, launcher, operational systems, and major components. In addition, the manual provides descriptive information on certain ground support equipment, and the transportation and handling of the launch vehicle and launcher. A reference list of support manuals for the Little Joe II launch vehicle is also included.
LAUNCH VEHICLE

The Little Joe II launch vehicle is a fin-stabilized airframe which uses solid propellant rocket motors as its source of propulsion power. Depending on the particular mission, the propulsion system may consist entirely of sustaining 'rocket motors, or a combination of sustaining and booster rocket motors. The vehicle incorporates the airborne portion of a command destruct system to terminate thrust of the sustaining rocket motor(s) at any time during the powered portion of flight. Some vehicles may also incorporate one or both of the following systems, depending on the particular mission: an attitude control system for missions requiring very accurate attitude control and a measurement system for missions requiring information on flight characteristics and system operation. An electrical system contains all components for supply, conversion, distribution and control of electrical power as required for the vehicle systems. See Figure 2 for an exploded view of .the launch vehicle. Airframe The launch vehicle airframe consists of a cylindrical body and four fins. The body has two main sections, a forebody approximately 19 feet long and an afterbody approximately 10. feet long. The body sections, both 15^ inches in diameter, are of semi-monocoque construction and are fabricated-from truncated form corrugated aluminum sheets stabilized by ring frames. The four>fins, each 50 square feet in area, attach -around the afterbody at equi-spaced locations.

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A
- LAUNCH ESCAPE ASSEMBLY

NOTE.
AIR CONDITIONING OUTLET ADAPTER ATTACHES IN DOOR 1 OPENING.

PAYLOAD UMBILICAL

EQUIPMENT AREA ACCESS DOOR (3) (SEE NOTE)

VEHICLE STATION 227.0 -VEHICLE AFTERBODY AIR CONDITIONING ACCESS DOOR EXTERNAL LONGERON (6) VEHICLE SUPPORT PAD (6)
FIN (4)

ELEVATION POSITION TRANSMITTER

TO LAUNCH PAD JUNCTION BOXES

DRIVE TRUCK (2) PLUG-IN REMOTE CONTROLLER RECEPTACLE OUTER RAIL

12.4.02.001F

Figure 1.

Launch Vehicle and Launcher

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TYPICAL ELECTRICAL INSTALLATION

VEHICLE FORESODY SUPPORT HOOK(2) SKIN (TYPICAL) | ,, ' -EQUIPMENT AREA ACCESS DOOR (3) STATION 34.75 MOTOR SUPPORT BULKHEAD

/EXTERNAL LONGERON(6)

FIN (4)

BODY FRAME (TYPICAL)

VEHICLE BODY FIXED FINS

TYPICAL ELECTRICAL INSTALLATION

STATION 227.0 SPLICEBHD. (FOREBODY)

VEHICLE FOREBODY

ALGOL MOT OR RECRUIT MOTOR (6)

ELEVON ACTUATOR FAIRING (4) OUTER MOTOR SUPPORT TUBE (6) MOTOR NOZZLE (TYPICAL) ELEVON (4)

STATION 227.0 SPLICE BHD. (AFTERBODY)

VEHICLE BODYATTITUDE CONTROL

AIR CONDITIONING DOOR (2)

STATION 347.0 VEHICLE MAIN BULKHEAD CENTER TUBE SUPPORT (TYPICAL)

FIN SKIN

FIN RIB (TYPICAL)

12.4.03.001C

FIN (4)

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Figure 2. Launch Vehicle - Exploded Viev

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The vehicle body incorporates three .major load introduction bulkheads, two in the afterbody and one in the forebody; "see Figure 3- A bulkhead at the aft (lower) end of the afterbody is the main structural member of the vehicle. The bulkhead is essentially a pyramid type structure consisting of two webs interconnected with metal cylinders, radial columns, and horizontal and radial members. This bulkhead includes mounting flanges and support provisions for seven sustaining rocket motors; special mount adapters are required to install the booster rocket motors on the sustaining motor mounting;flanges. Fittings that match support pads on the launcher, and fin aft attach fittings are also included on this bulkhead. The other major load introduction bulkhead in the afterbody, is located Just forward of the. main bulkhead and:Includes the fin forward attach fittings. The major load introduction bulkhead in the.forebody is located approximately'35 inches aft of the forward (upper) end of the section. This spoked bulkhead provides lateral support for the forward end of the sustaining rocket motor; the bulkhead has provisions for supporting a maximum of seven sustaining rocket motors. Some of the vehicle electrical equipment is mounted on the forward face of the bulkhead's outer ring. The bulkhead also accommodates hooks which attach to arms on the launcher to provide vehicle side support when assembled on the launcher, and fittings for.the attachment of guy wires to secure the vehicle and launcher to the pad during adverse weather conditohs. A. mounting ring, consisting of a metal ring with bolt holes and alignment pins, is located at the forward end of the forebody to accommodate the payload. Most rof the vehicle electrical equipment is installed in the forebody in the free space between the mounting ring and the major load introduction bulkhead. Three removable doors spaced at equal intervals around the forebody permit access to this area after the payload has been installed.- Removable wooden covers over the empty rocket motor openings in the bulkhead and removable wooden crawlway platforms within the area allow access to the electrical equipment. Six external T-section longerons are spaced around the afterbody for added support. Each longeron extends forward from an area at.the vehicle base adjacent to .one of the launcher mating fittings. Two access panels for ground air conditioning unit duct connections are located in the afterbody just forward of the main structural bulkhead. The duct connection assemblies are removed and the panels are installed when air conditioning is not required. . Fins The fins are a monospar structure, with the skin being stabilized by chordwise stiffeners and ribs. Access panels in each fin allow for the installation of measurement system components. Each fin attaches to the vehicle afterbody at three fittings, one forward and two aft. The forward fitting reacts shear from a portion of the torsional load, and the aft fittings react shear, drag and all fin bending.

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SUPPORT BULKHEAD STATION 34.75

ADJUSTABLE MOTOR SUPPORT PAD (TYPICAL) SKIN(REF) SUPPORT ARM HOOK (2) HOOK SUPPORT DETAILS MOTOR SUPPORT PAD DETAILS CENTER TUBE SUPPORT (6) OUTER MOTOR SUPPORT TUBE (6) SERRATED PLATE

CENTER MOTOR SUPPORT TUBE FIN FWD ATTACH FITTING (4)

SUPPORT BULKHEAD STATION 278.80

SUPPORT BULKHEAD STATION 347.0

I2.4.03.002A

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Figure 3 Main Support Bulkheads

' ,
Propulsion

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' .

The propulsion system can consist of all Aerojet Algol ID (sustaining) rocket motors, or a combination of Aerojet Algol ID and Thiokol Recuit XM19 (booster) rocket motors. The sustaining motors provide the .primary source of thrust; the booster motors provide a source of short duration, high thrust to supplement the sustaining motors at launch. The exact number, combination and' arrangement of motors depends on the power requirements for'the particular mission. Attitude Control System '

Vehicles which are to be equipped with an attitude control system will incorporate eleven control surfaces on each fin, an eleven hydraulic control system, an H202 monopropellant reaction control system, and an - autopilot. The eleven control system will be used during the major portion of flight within the atmosphere. The reaction control system will be used during the first few seconds of flight when airspeed is insufficient for eleven control, and again at high altitudes where dynamic pressure is insufficient for effective eleven control. The autopilot will control all in-flight functions of both systems. . Command Destruct System The command destruct system receives radio command signals generated by ground transmitters and produces output signals to terminate thrust of the sustaining motors and, optionally, to abort the payload. Measurement System The.measurement system consists of instrumentation and sensors that will obtain information on vehicle flight characteristics and system operation, and convert this data for transmission to ground receivers via a telemetering system. Five basic characteristics of the vehicle which are detected and measured by the system are: acceleration forces, vehicle and components temperatures, vehicle and motor pressures, system voltages, and vehicle body strain. A landline measurement system is used during ground operations to relay information to ground recorders via direct wire in lieu of the telemetering system. ' ' Electrical System The electrical system provides power for the measurement, ignition and attitude control systems, as required. The measurement system is powered by a single silver-zinc battery; ignition and attitude control system electrical power is supplied by two silver-zinc batteries connected in parallel. While the vehicle is groundborne, an external source of 28-volt dc power is applied to the systems via the vehicle umbilical power disconnects; vehicles equipped with

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neither the basic measurement system (as opposed to the landline measurement system) nor the attitude control system require external pover only. Control and regulation of the electrical system prior to umbilical disconnect during launch is accomplished through the use of switches, indicating lights and other electrical devices in the blockhouse and power building. LAUNCHER The launcher is a fabricated steel structure supported by two curved rails; see Figure k. The total weight of the launcher is approximately 100,000 pounds. Basic components include a pivot frame mounted on double-flange, cranetype trucks, an azimuth pivot pin assembly, support platform, mast, and elevation control screw jacks. A pneumatic system, consisting of a service panel on the left side of the support platform and two actuating cylinders, is used to retract an umbilical arm and two vehicle support arms on the launcher mast. Switches on the launcher control panel in the blockhouse control the operation of the pneumatic system. Launcher azimuth and elevation positions are adjustable and can be controlled from either a plug-in remote controller on a 50-foot extension cable or from the launcher control panel in the blockhouse. Azimuth angles up to ^5 degrees from a nominal direction can be selected within 1/2 degree accuracy. Elevation angles are restricted to within 15 degrees from the vertical position, within l/^t- degree accuracy. Two indicator systems, consisting of four-wire synchro transmitters, adjustable nulling resolvers, and digital readout indicators, provide launcher azimuth and elevation position indications. The azimuth position indicator transmitter is connected to the azimuth pivot pin assembly, and the elevation position indicator transmitter is located on the support platform pivot. The resolvers and digital readout indicators are mounted on the launcher control panel in the blockhouse. Heavy conduits, junction boxes and steel shielding protect the launcher control and position indicating circuit wiring and components from rocket blast. Pivot Frame The pivot frame forms the base of the launcher arid is constructed of welded steel I-beams. Two A-frames containing the vehicle support platform hinge fittings attach to the top side of the pivot frame and are braced by an X-frame; three "foot" assemblies attached to. the underside of the pivot frame, directly over the inner azimuth rail, provide additional launcher support. Azimuth Trucks Four azimuth trucks are used to support the corners of the pivot frame. Each truck has tvo wheels mounted in' tandem, and at an angle to follow the curved rails on the launch pad. Uplift anchors secure the trucks to the rails during high wind conditions. The tvo trucks on the outer rail are powered by remotely controlled electric motors which drive one of the wheels on the trucks to change launcher azimuth position. Steel plate shielding provides blast protection for the motors and drive mechanisms.

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PAYLOAD UMBILICAL HARNESS

UMBILICAL ARM PIVOT

ACTUATING CYLINDER BUST SHIELD UMBILICAL ARM ACTUATING CYLINDER

ACTUATING CYLINDER BLAST SHIELD SUPPORT ARM SINGLETREE AND ACTUATING CYLINDER VEHICLE SUPPORT ARM (2)

ELEVATION CONTROL SCREW JACK (2)

SCREW JACK MOTOR BLAST SHIELDING HARNESS SUPPORT MAST PLUG-IN REMOTE CONTROLLER RECEPTACLE

VEHICLE SUPPORT PAD (6)

A-FRAME (2) ELEVATION HINGE (2) ELEVATION TRANSMITTER VEHICLE SUPPORT PLATFORM

MAIN JUNCTION BOX

AZIMUTH TRANSMITTER

MOTOR AND GEARBOX BLAST SHIELDING SCREW JACK PROTECTIVE BOOT(2) FOOT ASSEMBLY (3) UPLIFT ANCHOR (4)

TO LAUNCH PAD JUNCTION BOXES

HARNESS STABILIZING CABLES

AZIMUTH PIVOT PIN INNER RAIL

IDLER TRUCK (2)

OUTER RAIL

12.4.09.001E

Figure k. Vehicle Launcher

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Pivot Pin

A six-inch diameter pin welded to a circular plate constitutes the azimuth pivot pin assembly. This pin-plate assembly is secured to the launch pad and engages a bronze bearing in the pivot pin'receptacle in one end of the pivot frame. The launcher pivots about this pin during changes in azimuth. Vehicle Support Platform The vehicle support platform is a welded steel I-beam structure hingemounted to two supporting A-frames. Components include a removable work platform grating, ladder, and trunnions for attachment of the elevation screw jacks. Tubular tripods and bipods support six vehicle mounting pads. Pins extending from two of the pads mate with slots in the vehicle afterbody to prevent shifting across the pitch axis when the platform is tilted. A pin in another of the pads is movable transversely, to ensure mating of the two pins at the pitch axis. The basic purpose of tl^is pin is to minimize shifting of the vehicle due to wind gusts, especially during lift-off. Elevation Control Screw Jacks Two interconnected screw jacks are hinge-mounted between the vehicle support platform and pivot frame and opposite the platform hinges to incline the platform to the desired elevation angle. A remotely controlled electric motor incorporating a bi-directional locking mechanism and a magnetic disk brake drives the screw jacks through a power transfer shaft. Steel shielding and bellows-type, flame resistant boots protect the screw jacks and motor from rocket blast. Mast The mast is a tapered, welded steel structure approximately 37-1/2 feet in height, with an access ladder from the base to a work platform at approximately the 23 foot level. Another ladder provides access to a payload umbilical arm, which is hinge-mounted to the top of the mast. A pneumatic cylinder, attached to the umbilical arm retracts the arm just prior to launch. Two retracting vehicle support arms at approximately the 30-foot level attach to hooks on the launch vehicle forebody. These support arms are adjustable and have a pneumatic actuating cylinder for retraction at lift-off to prevent interference with the vehicle. Steel angles located above the cylinders for the umbilical arm and support arms provide rocket blast protection; a flame-resistant boot covers the piston rod of the umbilical arm actuating cylinder. Both cylinders are serviced through a common nitrogen filler valve located in the pneumatic system panel box to the left of the support platform ladder. The panel box also contains a filter and relief valve, individual check valves, bleed valves, pressure switches, and gages for the respective cylinders.

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GROUND SUPPORT EQUIPMENT " '

A test console in the blockhouse and an equipment rack in the power transfer room incorporate the necessary equipment, controls, and indicators for monitoring and checking out the launch vehicle and launcher systems and performing launch operations. The test console panels include digital readout indicators, indicator lights, a dc voltmeter, pushbuttons and toggle switches, and a rotary selector switch. The console also incorporates circuit breakers on the right side of the cabinet and a relay panel on the back. The cabinet-type equipment rack in the power transfer room supports-panel-mounted relays, circuit breakers, resistors, diodes, and a timer. Stenciled referenced designations on the test console and equipment rack panels facilitate identification of components. A plug-in, portable remote controller with POWER ON indicator lights and pushbutton control switches provides bi-directional control of launcher azimuth and elevation at the launch pad. The unit plugs into a receptacle located adjacent to the main junction box on the launcher support platform and can be operated from any position on the launch pad within the 50-foot cable length. Additional ground support equipment consists of tie-down cables, vehicle and rocket motor hoist slings, support cradles and dollies. Special wrenches, calibration gages and tools are provided where required, along with assembly and work stands, covers and plugs. An optical alignment kit is used to check and level the launcher and launch vehicle. An air conditioning unit supplies a flow of temperature conditioned air into the rocket motor compartment of.the launch vehicle. Airflow, pressure, and temperature are manually variable and automatically maintained; a duct assembly with special adapters connects the air conditioning unit to the launch vehicle. A "suitcase" portable-type command destruct system test set is used to determine that the destruct system is functioning properly. The test set controls the input signal to the destruct.receivers with respect to signal strength, frequency, coding, and modulation deviation. The set also monitors the destruct system commands, voltages, and conditions.
TRANSPORTATION AND HANDLING

The launch vehicle and launcher are transported via common highway truck transports which operate under wide-load restrictions. The airframe afterbody and forebody are transported as a single unit cradled on an open low-boy trailer. The airframe fins are transported on cradles in a closed van. The fin cradles are mounted on a wheeled platform which may be used to roll the fins in and out of the van, and into the assembly building. Launcher components are installed on open truck trailers, some of the components such as the azimuth trucks being packaged and boxed for security and damage prevention. Standard packaging and crating techniques are used for shipment of hoisting slings, cradles, dollies, and various smaller items of equipment.

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The vehicle forebody, afterbody and fins are stored individually on vooden supports' before and after transport, and are enclosed in plastic bags for preservation. Relative humidity is controlled by desiccant material placed Inside each component's plastic bag. LAUNCH VEHICLE PERFORMANCE Approximate flight performance characteristics for various types of missions are shown on Figures 5 through 8. Motor configurations and firing sequences of the propulsion system are determined by thrust requirements for a particular mission. The motor configurations and firing sequences used to obtain the data shown on the figures range from a single Algol ID-six Recuit XM19 rocket motor combination with single-stage firing to a seven Algol ID configuration with three-stage firing; the payloads vary in weight from 24,2l6 pounds to 80,000 pounds and the vehicle launch weights, which include the payload weight, vary from 57*024 pounds to 246,537 pounds. All flight performance shown on the figures is based on launches made at an altitude of 4,000 feet, the 1959 ARDC Atmosphere (AFCRC-TR-59-267), zero wind velocity, and a rocket motor propellant grain temperature of 70 degrees F. Test launch vehicles for the lower altitude missions, Figures 5 and 8, will use the lower thrust motor configurations and single-stage firing. In addition to using the higher thrust motor configurations and staged firing, the test launch vehicles for the higher altitude missions, Figures 6 and 7* will be equipped with an attitude control system to maintain the launch angle during flight. Trajectory is controlled by varying the launch angle. Maximum altitude is attained by vertical launch, and the greatest horizontal range is attained at the minimum launch angle of 75 degrees. Maximum velocity for any given launch angle occurs near the point of motor burnout. The performance data shown on each figure are estimated results of a mission with specific combinations of launch angle, motor combination and vehicle launch weight. The curves show the estimated relationship of mach number, dynamic pressure, altitude and axial acceleration. Axial acceleration is shown only to motor burnout for the High Altitude Atmospheric Abort mission. Where data are shown beyond motor burnout, the payload is assumed to be still attached to the launch vehicle. Figure 5* giving results for a High Dynamic Pressure Abort mission, shows estimated data for a combination of one Algol ID and six Recruit XM19 rocket motors with single-stage firing, a launch angle of 83.5 degrees and a vehicle launch weight of 57*024 pounds. A payload weight of 24,2l6 pounds is included in the vehicle launch weight. The three sheets of Figure 6 show curves covering the launch vehicle boost portion of Very High Altitude Abort missions. After separation from the launch vehicle, service module motors are used to propel the command module to

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the very high altitude abort condition. The curves shown on Sheet 1 are "based on a launch angle of 75 degrees and a seven Algol ID motor configuration with a 4-2-1 firing sequence. The vehicle launch weight is 219*58? pounds and the payload weight is 53*050 pounds. .Sheet 2 reflects data for the same launch angle, motor configuration and firing sequence shown on Sheet 1 "but with an increase in payload weight to 80,000 pounds, making the vehicle launch weight 246,537 pounds. The data shown on Sheet 3 are based on a launch angle of 85 degrees, a seven Algol ID motor configuration with a 4-3 firing sequence, and a vehicle launch weight of 226,242 pounds, of which 63,074 pounds is payload. The three sheets of Figure 7 show data for High Altitude Abort missions. The curves shown on all three sheets are based on a launch angle of 85 degrees, a seven Algol ID'motor configuration and a vehicle launch weight of 190,200 pounds, of which 24,500 pounds is payload. Sheets 1 and.2 show the differences in performance between a-mission using a 4-3 firing sequence with no overlap between firings and a mission using a 4-3 firing sequence with a 10-second overlap between firings. Sheet 3 shows the performance for a mission using a 4-2-1 firing sequence with a 10-second overlap between firings. A comparison of the . data shown on Sheets 2 and 3 reveals the variation in performance obtained by changing from a 4-3 to a 4-2-1 firing sequence. Figure 8 shows data for a Maximum Dynamic Pressure Abort mission.- These data are based on a launch angle of 85 degrees and a two Algol ID-seven Recruit XM19 motor configuration with single-stage firing. The vehicle launch weight is 79*282 pounds, which includes a payload weight of 24,500 pounds.

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Figure 5-

High Dynamic Pressure ATaort

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SUPPORT MANUAL REFERENCE INDEX MANUAL

Hardware List Launch Vehicle Description Manual Operations Manual Checkout Manual Launch Vehicle Familiarization Manual Airframe Maintenance and Repair Manual Command Destruct System Maintenance and Repair Manual Electrical System Maintenance and Repair Manual (Applicable to Vehicle 12-50-1) Measurement System Maintenance and Repair Manual (includes Electrical System for Vehicles 12-50-2 and on and 12-51-1 and on) Propulsion System Maintenance and Repair Manual Launcher Maintenance and Repair Manual Launch Vehicle Wire Data Manual Launch Vehicle Console .GSE Manual Airframe Transportation and Handling Manual Attitude Control System Maintenance and Repair Manual (Applicable to Vehicles 12-51-1 and on)

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