This revision completely supersedes and replaces the 13 May 1963 

issue of this report.

Accession No.

C opy N o. 1 SID 62-702-2

APOLLO 

MAINTENANCE PLAN

NAS 9-150

Review Copy

Prepared By 

Apollo Logistics

N O R T H A M E R I C A N A V I A T I O N , INC. 

SPACE and I N F O R M A T I O N S Y S T E M S DIVISION
F O R E W O R D

The Apollo Maintenance Plan is presented in accordance with 

Exhibit I, Paragraph 3.5 of the Apollo NAS 9-150 Contract.

This issue constitutes the fourth revision of the original 

document which was first published as SID 62-202 on Msy 1, 1962. 

The Maintenance Concept, SID 62-702, has been incorporated as 

an integral part of this plan.
CONTENTS

Section Title Page

INTRODUCTION viii

I MAINTENANCE CONCEPT 1-1

1.1 SCOPE 1-1

1.1.1 General 1-1

1.2 MAINTENANCE OBJECTIVE 1-2

1.3 MAINTENANCE REQUIREMENTS 1-2

1.3.1 Maintenance Categories 1-2

1.3.2 Maintenance Functions 1-2

1.4 MAINTENANCE PLANNING 1-3

1.4.1 Maintenance Levels 1-3

1.4.1.1 A-Level Maintenance 1-5

1.4.1.2 B-Level Maintenance 1-5

1.4.1.3 C-Level Maintenance 1-5

1.4.2 Maintenance Areas 1-5

1.4.3 Maintenance Organization 1-5

II MAINTENANCE PLAN 2-1 

2.1 SCOPE 2-1 

2.1.1 General 2-1 

2.2 MAINTENANCE ANALYSIS 2-2 

2.3 MAINTENANCE CATEGORIES. 2-2
Section Title Page

2.3.3 Scheduled Maintenance 2-2 

2.3.2 Unscheduled Maintenance 2-3 

2.4 MAINTENANCE LEVELS AND FUNCTIONS 2-3 

2.4.1 A-Level Maintenance 2-3 

2.4.1.1 Testing - System Malfunction 2-6 

2.4.1.2 Repair 2-6 

2.4.1.3 Servicing 2-6 

2.4.1.4 Calibration and Adjustment 2-6 

2.4.1.5 Inspection 2-7 

2.4.1.6 Modification 2-7 

2.4.1.7 Overhaul 2-7 

2.4.2 B-Level Maintenance 2-7 

2.4.2.1 Testing - Replaceable Package 2-8 

2.4.2.2 Repair 2-8 

2.4.2.3 Servicing 2-9 

2.4.2.4 Calibration and Adjustment 2-9 

2.4.2.5 Inspection 2-9 

2.4.2.6 Modification 2-9 

2.4.2.7 Overhaul 2-10 

2.4.3 C-Level Maintenance 2-10 

2.4.3.1 Modification, Repair and Overhaul 2-10 

2.5 MAINTENANCE AREAS 2-10 

2.5.1 S&ID-Downey 2-11 

2.5.1.1 Bench Maintenance Area 2-11 

2.5.1.2 Manufacturing Production Area 2-11
Section Title Page

2.5.2 Florida Facility 2-11

2.5.2.1 Operations and Checkout Area 2-14

2.5.2.2 Launch Area 2-14

2.5.2.3 Remote Areas 2-14

2.5.2.4 Bench Maintenance Area 2-15

2.5.3 White Sands Missile Range 2-15

2.5.3.1 Mission Abort Area 2-17

2.5.3.2 Propulsion Systems Development Facility 2-17

2.5.4 Banned Spacecraft Center 2-18

2.5.4.1 Assembly and Checkout Area 2-18

2.5.4.2 Test Chamber Area 2-18

2.5.4.3 Bench Maintenance Area 2-20

2.5.5 El Centro Parachute Test Facility 2-20

2.5.6 Marshall Space Flight Center 2-20

2.5.7 Subcontractor Maintenance 2-21

2.5.7.1 Subcontractor Facilities 2-21

2.5.7.2 S&ID-Downey Facility 2-21

2.5.7.3 Test Sites 2-21

2.6 PREINSTALLATION ACCEPTANCE (PIA) 2-21

2.6.1 PIA Spares 2-22

2.6.1.1 PIA Spares Classification 2-22

2.6.2 PIA Implementation 2-22

2.7 MAINTENANCE DOCUMENTATION 2-22

2.7.1 Test and Inspection Record 2-23

2.7.1.1 Test Preparation Sheet 2-23
Section Title Pa g e

2.7.1.2 Test Preparation Modification Sheet 2-25

2.7.1.3 TPS & TPMS Index 2-25

2.7.1.4 Discrepancy Record 2-25

2.7.1.5 Discrepancy Record Squawk Sheet 2-30

2.7.1.6 Discrepancy Record Index 2-30

2.7.1.7 Part Removal Record 2-30

2.7.1.8 Installed Equipment Serialization Record 2-35

2.7.1.9 Operating Time and Discrepancy Record 2-35

2.7.1.10 Operational Time Change Items 2-35

2.7.2 Materiel Condition Identification 2-35

2.7.2.1 Serviceable, Incomplete Status & Hold Tag 2-35

2.7.2.2 Reparable Tag 2-41

2.7.2.3 Rejected or Condemned Tag 2-41

2.8 Support Manuals 2-41

APPENDIX 

Bibliography B-1

Thru

B-4

Glossary of Terms G-1 

Thru G

-14

LIST OF ILLUSTRATIONS

Figure Title Page

1-1 Maintenance Levels 1-4

1-2 Maintenance Management 1-7
Figure Title Bags

2-1 A & B Level Maintenance Flow 2-4

2-2 C-Level Maintenance Flow 2-5

2-5 Apollo Manufacturing Organization, S&ID-Downey 2-12

2-4 S&ID Apollo Program Organization, Florida Facility 2-13

2-5 S&ID, Apollo Program Organization, White Sands Missile Range 2-16

2-6 S&ID, Apollo Program Organization, Manned Spacecraft Center 2-19

2-7 Test Preparation Sheet 2-24

2-8 TPS & TPMS Flow Diagram 2-26

2-9 Test Preparation Modification Sheet 2-27

2-10 Test Preparation Sheet Index 2-28

2-11 Discrepancy Record 2-29

2-12 Discrepancy Record and Discrepancy Record Squawk Sheet Flow 

Diagram 2-31

2-13 Discrepancy Record Squawk Sheet 2-32

2-14 Discrepancy Record Index 2-33

2-15 Part Removal Record 2-34

2-16 Installed Equipment Serialisation Record 2-36

2-17 Operating Time (Sheet 1 of 2) 2-37

2-18 Discrepancy Record (Sheet 2 of 2) 2-38

2-19 Operational Time Change Items 2-39

2-20 Serviceable, Incomplete Status Hold Tag 2-40

2-21 Reparable Tag 2-42

2-22 Rejected or Condemned Tag 2-43
Figure 2-5. Apollo Program Organization, White Sands Missile Range
INTRODUCTION

In accordance with the recent NASA request, this document combines both the Apollo Maintenance Concept and the Apollo Maintenance Plan. Section I comprises the conceptual presentation.

The intent of the Concept is to summarize those basic elements 

and considerations that are essential in formulating an effective 

maintenance support activity. Section II contains the plan.

The purpose of the Plan is to describe what maintenance is, what 

its restraints are, where it will be performed, and who is 

responsible for its management and conduct. A Glossary of Terms 

is included at the end of the document. This revision reflects 

the views of Division management pertinent to maintenance planning, 

requirements, responsibilities, and activities that are within 

the contractor's scope of authority.
I. MAINTENANCE CONCEPT

1.1 SCOPE

This section presents the contractor's philosophy and approach regarding the 

development of effective maintenance support for Apollo test and mission 

objectives. It is the basic intent of the Concept to establish the 

principles upon which a maintenance activity will be structured, as well as 

to outline the parameters within which it will operate. Fundamental considerations such as objective, retirements, and planning, are dealt with 

in the body of the text, and corollary factors such as maintenance levels, 

maintenance areas, and maintenance functions are also covered.

1.1.1 General

The philosophy expressed in this Concept is principally based on the contractual requirement that NAA/S&ID will perform and/or control all maintenance associated with Apollo Spacecraft, ground support equipment, and spares 

(end items and materiel) provided by the contractor. Within the context of 

this document, maintenance is defined as those functions which are required 

to retain materiel in, or restore it to, a serviceable condition.

The Concept, in substance, results from a detailed study of the Apollo 

Program Plan, the General Test Plan, the Facilities Plan, the Quality Control 

Plan, the Reliability Plan, and the Master Development Schedule. It is 

equally the result of a thorough examination of Apollo test and mission 

objectives, and a critical analysis of what will be required from a maintenance standpoint to support them.
1.2 M AINTENANCE OBJECTIVES

First among the considerations to be resolved before a maintenance activity 

is established are the objectives to be achieved. The Apollo maintenance 

objectives are: To maintain system reliability, to ensure operational 

capability, and to provide optimum maintenance support for Apollo Test and

Operations in order that tests may be carried out as scheduled.

1.3 M AINTENANCE REQUIREMENTS

The determination of requirements that are essential to the performance of 

maintenance is next in importance after maintenance objectives have been 

established. These requirements are of a manifold nature and have to do 

with such considerations as site location, programmed capability, provisioning support , test and operational schedules, And the economy of 

maintenance operations. Considerations that pertain expressly to maintenance activities are defined and described in succeeding paragraphs.

1.3.1 Maintenance Categories

For the purposes of effective planning, scheduling and provisioning, maintenance is aliened under two distinct categories. These categories are 

scheduled maintenance and unscheduled maintenance. Scheduled maintenance 

is preventive in nature and can be predicted with reasonable accuracy. Unscheduled maintenance is corrective in nature, cannot be predicted, results 

from a deficiency or discrepancy, and usually arises during a test, operation, 

or scheduled maintenance activity. The various functions that are performed 

as a consequence of scheduled and unscheduled maintenance requirements are 

described below.

1.3.2 Maintenance Functions

Maintenance comprises many functions, each of which is essential to the 

successful accomplishment of the maintenance objectives. These functions
include inspection, servicing, adjustment, calibration, modification, 

repair and overhaul. The depth at which these functions may be performed 

is directly influenced by the maintenance capability programmed for the 

individual test site.

1.4 MAINTENANCE PLANNING

In order to achieve the maintenance objectives previously expressed, 

extensive analysis and planning are required. Considerable attention must 

be given as to where maintenance will take place, what depth of maintenance 

is possible at each test site, and who is organizationally responsible for 

maintenance management at various locations. Consideration must also be 

given to the economy of operation, and to the corollary need for avoiding a 

duplication of facilities or equipment. A studied analysis of projected 

Apollo Program tests and operations has been instrumental in determining 

the maintenance requirements at various areas, and has indicated the need 

to establish varying levels of maintenance to support test and operations 

in these areas.

1.4.1 Maintenance Levels

The contractor has determined that maintenance objectives can best be 

achieved by establishing three distinct levels of maintenance capability. 

These levels will hereafter be referred to as A, B, and C. This division 

of maintenance lends itself to programming facilities, equipment and 

personnel in an economical manner to meet the requirements of test and 

operations. It also avoids the provisioning of costly facilities and equipment at each area, and still provides an optimum capability that will be 

responsive to requirements. Levels of maintenance relating to electronic 

systems, mechanical systems, and ground support equipment are exemplified 

in Figure l-l.
Figure 1-1. Maintenance Levels
1.4.1.1 A-Level Maintenance. Maintenance accomplished at this level is generally

limited to inspection, test, removal and installation of replaceable packages 

or components such as drawers and panel assemblies, end system verification.

1.4.1.2 B-Level Maintenance. This level of maintenance provides a greater capability 

and depth of penetration than that assigned to A-Level. For example, a 

replaceable package or component may be repaired through replacement down to 

a replaceable serialized unit, i.e ., an amplifier or valve assembly. B-Level 

maintenance is generally available at each test site„

1.4.1.3 C-Level Maintenance. This level of maintenance provides a total maintenance 

capability. Maintenance actions performed at this level include extensive 

modification, repair, and overhaul. The contractor 's and subcontractors' 

factory facilities are utilised to support C-Level maintenance as required.

1.4. 2 Maintenance Areas

Review of the Apollo Program Plan indicates that tests and operations will 

be performed at S&ID-Dcwney, Florida Facility, White Sands Missile Range, 

and Manned Spacecraft Center. Various levels of maintenance will be performed at these areas in support of test and operations. Test and operations 

are also programmed at Marshall Space Flight Center and at El Centro, but 

no contractor maintenance effort has been programmed by the contractor.

1.4.3 Maintenance Organization

The nature of the Apollo Program does not lend itself to an organizational 

separation of maintenance from test and operations at the Test Sites. The
contractor organisation at individual Test Sites is set up to perform 

both test and operations and maintenance. The contractor and its subcontractors are organised to provide extensive maintenance at factory 

facilities. The contractor's maintenance management organization, depicting functional responsibilities and subcontractor and customer interfaces, 

is presented in. Figure l-2.
Figure 1-2. Maintenance Management
II. MAINTENANCE PLAN

2.1 SCOPE

This section defines and describes what maintenance is, what its constraints 

are, where it is performed, and who is responsible for its accomplishment. 

Illustrations that depict maintenance flow, maintenance organization, and 

maintenance documentation are also included.

2.1.1 General

This plan was developed to deal expressly with pure maintenance activity 

requirements, responsibilities, and functions. The organisation, system 

and methods described in the succeeding test resulted from a review of 

other Apollo planning documentation, a thorough evaluation of program 

requirements, and the performance of detailed support analyses. Though 

not covered in this document, certain essential factors such as facilities, 

quality control, trainings, and other support functions or services have 

been considered. Information on these subjects is provided in the publications listed in the Bibliography appended to this document.

As used herein, maintenance applies to end items and materiel that have 

completed the manufacturing cycle, and have been transferred to the 

customer by a properly executed Form DD-250.
2.2 MAINTENANCE ANALYSIS

Maintenance analyses shall be performed on all Apollo spacecraft, ground 

support equipment and trainers provided by the contractor and its subcontractors. The objective of these analyses is to determine the maintenance capability and maintenance support required for each end item of equipment that is within the scope of contractor responsibility. Principal 

elements of the maintenance analysis are the spares summary, the special 

tools and equipment summary, and the task and equipment analysis. The 

Apollo Support Plan, SID 62-702-1, describes the system and procedures used 

to develop these analyses from basic input material and information sources..

2.3 MAINTENANCE CATEGORIES

Two categories of maintenance are involved in keeping Apollo end items operable and support materiel serviceable. These categories are identified as 

scheduled maintenance and unscheduled maintenance. Scheduled maintenance 

consists of predictable tasks that must be performed at periodic intervals 

in order to assure the reliability and availability of a system. The Apollo 

Master Repair Schedule (MRS) SID 63-903, provides a forecast of predictable 

maintenance requirements. This document is defined and described in detail 

in the Apollo Support Plan, SID 62-702-1, Unscheduled maintenance consists 

of tasks performed at unpredictable intervals due to discrepancies or 

deficiencies within a system.

2.3.1 Scheduled Maintenance

Scheduled maintenance will be performed on spacecraft, ground support equipment and associated spares at periodic intervals throughout their service 

life. This category o f maintenance is preventive in nature and is intended 

to retain equipment and materiel in a serviceable condition. Inspection 

and servicing are two examples of scheduled maintenance functions.
2.3.2 Unscheduled Maintenance

Unscheduled maintenance wi11 be performed on spacecraft, ground support equipment and spares as a result of discrepancies and deficiencies found during 

test operations or during scheduled inspect ions. This category of maintenance is corrective in nature and is intended to restore equipment to a 

serviceable condition. Fault isolation and repair are two examples of unscheduled maintenance functions.

2.4 MAINTENANCE LEVELS AND FUNCTIONS

Three levels of maintenance (A, B, and C) have been established to provide 

realistic and economical support through all stages of the Apollo Program. 

These levels are commensurate with equipment configuration and location, 

and therefore determine the scope of maintenance functions which may be performed, i .e., fault isolation, verification, repair, servicing, calibration, 

adjustment, inspection, modification, and overhaul. A- and B-Level maintenance flow is illustrated in Figure 2-1, and C-Level maintenance flow is 

illustrated in Figure 2-2.

2.4.1 A-Level Maintenance

This level of maintenance relates to functions and tasks that are performed 

on an installed system of flight hardware or GSE. It is maintenance at the 

system level. A-Level repair of a system is accomplished by the removal of 

a faulty replaceable package, repair of the package or replacement with a 

qualified spare, and verification of the system. These activities will 

include in-place servicing and adjusting that can be performed through 

external access points.

All A-Level maintenance performed must be within the verification capability 

of available ground support equipment that is common to systems and inte­
Figure 2-2. C-Level Maintenance Flow
grated systems checkout. This level of maintenance is intended to return 

a system to an operational condition in the minimum amount of time.

2.4.1.1 Testing - System Malfunction.When a system malfunction occurs in an 

Apollo end item, a test will be conducted with available GSE to isolate 

the fault to a replaceable package in its installed configuration. At 

this level of maintenance, test points will be confined to those that are 

externally located. The GSE used to detect and isolate s fault must also 

be capable of system verification after repair has been accomplished.

2.4.1.2 Repair. The repair of Apollo equipment at this level of maintenance consists of the removal of replaceable packages suspected or determined to be 

faulty, and the installation of serviceable packages. It also includes the 

removal and installation of externally accessible items such as bulbs or 

indicator lens, as well as limited structural repair not requiring disassembly, structural reverification, or special tools and test equipment.

No repair will be attempted at this level of maintenance that cannot be 

performed with available certified equipment, spares, facilities, and 

trained personnel.

2.4.1.3 Servicing. The elements of servicing at this level of maintenance include 

cleaning, lubricating, charging, flushing, purging, and the replacement of 

filters and desiccators. All elements of this maintenance function are 

confined to servicing at externally accessible service points. There will 

be no requirement to remove replaceable packages at this level of maintenance.

2.4.1.4 Calibration and Adjustment. Certain ground support equipment and all test 

measurement equipment are subject to periodic calibration and adjustment.

At this level of maintenance, calibration and adjustment of an assembled
system consists of that which can be accomplished at externally available 

test and adjustment points. The performance of these tasks will be constrained by the verification capability of available equipment provided 

for system operational checkout.

2.4.1.5 Inspection. This level of inspection involves the verification of the 

physical and functional integrity of a system or group of systems while in 

the operational configuration. It also includes inspections that are 

associated with the verification of all A-Level maintenance tasks.

Within the maintenance aspect, inspection will occur as a result of a 

completed maintenance action (conformance verification). An inspection 

that reveals a discrepancy can also result in a requirement to perform unscheduled maintenance (discrepancy identification}. The removal of equipment access doors and inspection plates also constitutes a maintenance 

action (accessibility requirements).

2.4.1.6 Modification. This level of modification pertains to limited structural 

changes on spacecraft and ground support equipment that will not require 

reverification of structural integrity. Modification at an A-Level of 

maintenance also includes the exchange of a replaceable package for a new 

configuration or a modified package. It further includes authorised modifications which are possible while the system is in an operational configuration.

2.4.1.7 Overhaul. This activity does not apply to A-Level maintenance.

2.4.2 B-Level Maintenance

This level of maintenance pertains to functions and tasks that are performed 

on a replaceable package. It is maintenance at the package level. B-Level
repair of a package is accomplished by the removal of a faulty item, and 

replacement down to the serialized unit level with a qualified spare.

Repair at this level can only be accomplished with the package removed from 

the end item system of which it is a portion, and will take place in the 

Bench Maintenance Area where isolation of tbs failure as well as verification of the repair can be accommodated.

B-Level maintenance will include all tasks that can be performed on a replaceable package in the bench maintenance area, except the disassembly of replaceable serialized units or components that make up the replaceable package. 

Internal access points can be serviced, or adjusted and tested as needed to 

return a replaceable package to an operable condition. On electronic equipment, a replaceable serialized unit will be of the type that doss not require 

soldering for removal or installation... it may be a plug-in or threaded 

fastener type.

2.4.2.1 Testing - Replaceable Package. The testing of a malfunctioned replaceable 

package that has been removed from an end item will be performed at the site 

Bench Maintenance Area. At this level of maintenance, available equipment 

(BME) will be capable of isolating the fault in a replaceable package to a 

replaceable serialized unit or units, and will verify the serviceability of 

the package after repair has been made.

2.4.2.2 Repair. Apollo equipment repair at this level of maintenance applies particularly to the restoration of replaceable packages to a serviceable condition 

after malfunction and removal from a system. After the malfunction is 

isolated to a replaceable serialized unit, repair will consist of removing 

the faulty unit and installing a serviceable spare.
Repairs that are more complex and require a deeper penetration than that 

involved in the exchange of a replaceable serialised unit will be considered 

C-Level maintenance which is covered under the overhaul phase. Under certain 

conditions at a Test Site, an exception might be made to allow the exchange 

of a faulty part in a replaceable unit with a provisioned spare (C-Level 

maintenance).

2.4.2.3 Servicing. The elements of servicing at this level of maintenance are 

essentially the same as those described under A-Level, but at a greater 

depth. Consequently, the performance of this function is extended to include 

the removal of replaceable packages or units in order to permit servicing at 

internally located access points.

2.4.2.4 Calibration and Adjustment. At this level of maintenance, access to a

replaceable package is required in order to accomplish calibration and adjustment, These functions shall only be performed on a replaceable package or 

one of its replaceable units in a Bench Maintenance environment. The calibration or adjustment of equipment that cannot be verified with available 

BME or standard certified test equipment will be avoided.

2.4.2.5 Inspection. The performance of inspection at this level of maintenance 

applies particularly to the verification of integrity of equipment assigned 

to the Bench Maintenance Area for maintenance. It also includes the verification and acknowledgement of all maintenance tasks performed at the B-Level.

2.4.2.6 Modification. End item modification at this level of maintenance generally 

comprises the exchange of a replaceable unit in a replaceable package with 

a modified unit. However, it may also include any end item component 

modification that has been approved, and that can be performed within the 

parameters of B-Level maintenance.
2.4.2.7 Overhaul. This activity dees not apply to B-Level maintenance.

2.4.3 C-Level Maintenance

This level of maintenance provides the most comprehensive capability of the 

three levels established. It encompasses all maintenance that lies beyond 

the scope of levels previously described. C-Level maintenance will be 

performed at the contractor's facility or a subcontractor's facility, where 

all of the provisions for modification, repair, or overhaul that can be 

accomplished are available. The maximum depth of penetration is possible in 

C-Level maintenance, since fault isolation can be carried to the lowest replaceable part or group of parts with factory equipment. This equipment will 

provide a verification capability sufficient to accomplish the certification 

of all items repaired.

To prevent the costly duplication of test equipment, the contractor and its 

subcontractors will perform modification, repair and overhaul with the same 

facilities as used in manufacturing.

2.4.3.1 Modification, Repair and Overhaul. The modification, repair and overhaul of 

Apollo end items at a C-Level of maintenance accommodates the performance of 

these functions to the level required, e.g., complete modification, repair or 

overhaul to the lowest part level...s uch as a resistor, diode, seal or bracket. 

The fault isolation and repair verification capability of available ground 

support equipment will permit the accomplishment of all maintenance required.

2.5 MAINTENANCE AREAS

Maintenance of Apollo end items and materiel will be performed at the contractor's facility, at subcontractors' facilities, and at the Test Sites.

The contractor's and subcontractors' facilities will be programmed to accommodate C-Level maintenance, and the test sites will be programmed to support 

B-Level maintenance.
2.5 .1 S&ID-Downey

All levels of maintenance support for end items and materiel are provided 

by the contractor at S&ID-Downey. Manufacturing provides the organization 

(see Figure 2-3) and facilities to support Downey Test Operations as well 

as Test Site requirements. Manufacturing Bench Maintenance is organised 

and oriented to support Downey Test Operations, as well as to support C-Level 

maintenance requirements originating at the Test Sites.

2.5.1.1 Bench Maintenance Area. The Bench Maintenance Area at S&ID-Downey is

located in Building 290. This area is equipped to permit A, B, and some 

C-level modification, repair and overhaul of Apollo end items and materiel. 

Subcontractor maintenance equipment and personnel are also situated in the 

area to provide specialised testing, repair, and certification of subcontractor furnished items. To preclude the compromise of hardware reliability 

during maintenance, this ares is equipped to provide a high degree of 

environmental control, i.e., cleanliness. humidity, end temperature control.

2.5.1.2 Manufacturing Production Area. MAA/S&ID manufacturing production facilities

are located within the Downey complex. This complex provides back-up 

support for C-level maintenance requirements that are generated at Downey 

and the Test Sites. The same organization, facilities, equipment, and 

personnel which were utilized for the initial fabrication of Apollo hardware will be used to perform modification repair and overhaul of end items 

and materiel.

2.5.2 Florida Facility

The contractor maintains an activity at the Florida Facility to provide 

maintenance support for Apollo Test Operations at that site. Apollo Test 

and Operations, (see Figure 2-4) at the Florida Facility, is organized
Figure 2-3. Apollo Manufacturing Organization, S&ID-Downey
Figure 2-4. S&ID Apollo Program Organization, Florida Facility
to provide A- and B-Level maintenance support. There are three principal 

areas at this site where maintenance will be performed. These are the 

Operations and Checkout Area, the Launch Area, and the Beach Maintenance 

Area.

2.5.2.1 Operations and Checkout Area. Maintenance tasks performed in this area

support the receiving and checkout of spacecraft, systems, subsystems, and 

related ground support equipment prior to transfer to the launch area. 

Maintenance support in this area is generally limited to A-Level and involves 

the inspection, test, adjustment, calibration, removal, installation, and 

verification of replaceable packages. Modification that is within the 

capability of programmed equipment and personnel may also be performed in 

this area. All B-Level maintenance requirements that originate in the 

Operations and Checkout Area are supported by the Bench Maintenance Area.

2.5.2.2 Launch Area. Maintenance tasks performed in this area involve the mating 

of launch vehicle and spacecraft, with subsequent servicing and preflight 

checkout. Maintenance requirements occurring in this area are predominantly of an unscheduled nature. Launch Area maintenance tasks will 

generally be limited to the A-Level. B-Level maintenance requirements 

originating in this area will be supported by the Bench Maintenance Area.

2.5.2.3 Remote Areas. In addition to the three principal areas cited above,

certain maintenance tasks will be performed in the Static Firing Facility, 

Cryogenic Facility, Radar Bore Sight Facility, Parachute Facility,

Hypergolic Facility, Ordnance Facility, and Environmental Control Facility. 

Maintenance tasks performed in these areas are generally limited to A-Level
and consist of such functions as inspection, servicing, calibration, and 

minor modification. The site Bench Maintenance Area will provide B-Level 

support for the Remote Areas.

2.5.2.4 Bench Maintenance Area. This area has been programmed to provide B-Level 

Maintenance support for the Operations and Checkout Area, the Launch Area, 

and the Remote Areas, and will have repair and recertification capabilities 

to a replaceable package level. Maintenance tasks performed in the Bench 

Maintenance Area will consist primarily of fault isolation in replaceable 

packages to the lowest replaceable unit, and recertification of the package 

when repair is completed. Certain modification tasks will also be performed 

in the Bench Maintenance Area. These will include the installation of 

modified replaceable units in replaceable packages, as well as other 

specifically authorized changes that are within the verification capability 

of available GSE. Maintenance requirements originating at the site that 

are beyond the B-Level capability will be referred to the contractor or 

subcontractor as appropriate. These items are routed in accordance with 

the Source Maintenance Recoverability (SMR) code which designates the repair 

location. The SMR code is defined and described in the Apollo Support Plan, 

SID 62-702-1.

2.5.3 White Sands Missile Range

Maintenance support requirements exist at WSMR in two widely separated 

locations, and for two entirely different test operations. These locations 

are the Mission Abort Area and the Propulsion Systems Development Facility 

(PSDF). Maintenance activities at Mission Abort and PSDF are under the 

immediate direction of their respective Chief of Test Operations and these, 

organizationally, are subordinate to the overall direction of the WSMR 

Test Manager (see Figure 2-5).
Maintenance requirements originating at Mission Abort or PSDF which are 

beyond the programmed capability of these areas will be referred to the 

contractor or subcontractor. The SMR code assigned to reparable items 

designates where they will b e repaired. This inform ation is contained in 

the Site Support List.

2.5.3.1 Mission Abort Area. The Mission Abort Area contains a Vertical Assembly 

Building (VAB) and a Launch Facility. Receiving inspection and checkout 

of systems and ground support equipment takes place in the VAB, Scheduled 

and unscheduled maintenance tasks performed in this building are all confined to the A-Level. Stacking and integrated system checkout are conducted 

at the Launch Facility, utilizing the launch pad and service tower. Maintenance tasks performed in this area are generally of an unscheduled nature, 

and are also confined to the A-Level. Modifications of a minor nature that 

fall within an A-Level capability will be performed at both the VAB and the 

launch Facility.

A Meter Room, situated in the VAB, is equipped with sufficient bench maintenance equipment (BME) to provide B-Level maintenance support for mission 

abort test operations.

The Technical Area of the WSMR complex contains laboratory and test facilities 

far more extensive than those located at the Apollo test areas. Arrangements 

will be made through NASA to obtain support from these facilities when the 

maintenance capability at the Mission Abort Area proves inadequate.

2.5.3.2 Propulsion Systems Development Facility. Maintenance is performed in two 

locations at the PSDF. These locations are the Test Fixture Area and the 

Meter Room. Maintenance tasks performed in the Test Fixture Area generally 

fall within the A-Level and involve receiving inspection, servicing, cali­
bration, minor modification, etc. The Meter Room contains BME that provides 

B-Level maintenance support to the Test Fixture Area.

As with the Mission Abort Area, arrangements will be made to obtain support 

from the Technical Area of the WSMR complex when the maintenance capability 

at PSDF proves inadequate.

2.5.4 Manned Spacecraft Center

Spacecraft environmental test programs encompassing all of the multiple 

system environmental chamber (thermal-vacuum) tests will, be conducted in 

the Enviro nmental Proof Simulator Facility at the Manned Spacecraft Center 

(MSC), Maintenance performed in support of these tests will occur in the 

Assembly and Checkout Area, the Test Chamber, and the Bench Maintenance 

Area. Trainer Maintenance is the responsibility of MSC. The organization 

responsible for maintenance at MSC is shown in Figure 2-5.

2.5.4.1 Assembly and Checkout Area. The receipt, assembly and checkout of spacecraft, prior to insertion in the Test Chamber, will be conducted in the 

Assembly and Checkout Area located adjacent to the Test Chamber, Maintenance tasks performed in this area will generally be confined to the A-Level, 

and will consist of inspection, servicing, testing, etc. Minor modifications that fall within the A-Level capability may also be performed in 

this area. Maintenance requirements originating in this area that are 

beyond the A-Level will be supported by Bench Maintenance.

2.5.4.2 Test Chamber Area. Maintenance tasks performed in this area will generally 

be of an unscheduled nature and confined to the A-Level. These tasks will 

include fault isolation to the removable package level, as well as removal, 

installation and system verification.
Figure 2-6. S&ID, Apollo Program Organization, Manned Spacecraft Center
2.5.4.3 Bench Maintenance Area. The Bench Maintenance Area at MSC is intended to

provide B-Level maintenance support to the Assembly and Checkout Area and,

in some instances, to maintenance requirements originating in the Test 

Chamber.

Maintenance tasks performed in. this area will primarily involve fault 

isolation of replaceable packages to the lowest replaceable unit, and 

certification of the unit when repair is completed. Certain modification 

tasks will also be performed in the Bench Maintenance Area. These will 

include the installation of modified replacement units in replaceable 

packages, as well as other specifically authorized changes that are within 

the verification capability of available GSE. Maintenance requirements 

originating at MSC that are beyond the B-Level will be refered to the

contractor or subcontractor as designated in the SMR code. The Site Support 

List contains SMR code information.

2.5.5 El Centro Parachute Test Facility

Northrop Ventura has prime responsibility at the El Centro Parachute Test 

Facility. However, NAA will provide maintenance support from S&ID-Downey 

on an "as required" basis. A small stock of spares is maintained at 

El Centro, and NAA/S&ID provides a parts man and liaison engineer to the 

facility.

2.5.6 Marshall Space Flight Center

The extent of maintenance to be performed at Marshall Space Flight Center 

(MSFC) is presently unknown. When information on the subject is available, 

it will be included in the plan. Once defined, the maintenance effort 

required at MSFC shall be a matter of separate contractual coverage.
2. 5.7 Subcontractor Maintenance

Major subcontractors provide maintenance support at their respective manufacturing facilities, at S&ID-Downey, and at the test sites. Each of these 

subcontractors have prepared and submitted a support plan which delineates 

the maintenance support they will provide. These plans have been approved 

by the contractor.

2. 5.7.1 Subcontractor Facilities. Equipment and personne1 to accomodate C-Level

maintenance will be available at subcontractor facilities to provide maximum product support.

2.5.7.2 S&ID-Downey Facility. Major subcontractors wi11 provide equipment and

personnel for the Downey Bench Maintenance Area to support the system, subsystem, and component maintenance requirements of their product. The maintenance performed here will generally be confined to the B-Level, whereas 

C-Level maintenance will usually be performed at their respective manufacturing facilities.

2.5.7.3 Test Sites. Major subcontractors will maintain field engineers and field 

service engineers at the Test Sites to advise and assist NAA/S&ID maintenance personnel in the performance of maintenance on subcontractor products. 

Major subcontractors will provide technicians to familiarize and train the 

contractor's maintenance personnel in the operation and maintenance of subcontractor products.

2.6 PREINSTALLATION ACCEPTANCE (PIA)

Preinstallation acceptance of designated spares has been established as a 

requirement to ensure that the reliability of spacecraft and GSE systems and 

subsystems will not be compromised.
2.6 .1 PIA Spares

Spacecraft end supporting GSE spares are classified in accordance with 

certain criteria and require PIA at varying depths and intervals. Some of

the criteria that is considered in determining the classification of PIA 

spares are criticality, storage, material composition, reliability history, 

installation manhours, complex circuitry, and effect on vehicle system or 

GSE when installed.

2.6.1.1 PIA Spares Classification. Classification of PIA spares are as follows: Class 

1 - Critical or complex items clearly requiring site receiving, 

periodic, and preinstallation functional verification.

Class 2 - Items requiring site receiving and preinstallation test.

Class 3 - Items requiring site receiving, periodic, and preinstallation test. Subsequent to preinstallation test, items will 

be calibrated.

2.6 .2 PIA Implementation

Preinstallation acceptance of designated spacecraft end supporting GSE 

spares will be performed at S&ID-Downey and at the Test Sites. The performance of PIA will be accomplished by M anufacturing Bench Maintenance 

and subcontractor maintenance support at S&ID-Downey, and site bench maintenance at the Test Sites. Maintenance tasks involved in PIA will generally 

fall within the B-Level capability.

2.7 MAINTENANCE DOCUMENTATION

Documentation is an essential requirement of the maintenance support activity, 

and is used to maintain control, to provide historical records, and to 

identify the condition of Apollo end items and materiel. Succeeding para­
graphs describe the documentation that is utilized to fulfill these requirements, and illustrations of the various forms involved in processing hardware through the maintenance cycle are also included.

2.7.1 Test and Inspection Record 

A work book system will be initiated for the purpose of documenting each 

maintenance action performed on Apollo end items throughout their service 

life. The system is embodied in the Test and Inspection Record (TAIR) Book 

which comprises a series of forms, and will be used to provide definitions, 

authorization, recording, sign-off, and verification of all work accomplished 

on the individual item involved. A TAIR Book will be provided for 

other materiel as deemed necessary. 

Apollo Quality Control will maintain the TAIR Books and assure that all 

work entries have been complied with. The following paragraphs provide a 

description of the purpose and use of TAIR Book forms that pertain to maintenance of Apollo end items. 

2.7.1.1 Test Preparation Sheet. The Test Preparation Sheet (TPS) is prepared 

to authorize and implement testing or test scheduling, maintenance, and configuration changes on Apollo end items. Ths TPS (see Figure 2-7) is used to initiate or 

document the following: 

a. Perform work to accomplish a temporary configuration change.

b. Perform work to accomplish changes authorized by a released

Engineering Order (EO) or Field Engineering Order (FEO). 

c. Perform tests in accordance with an Operational Test Procedure (OTP)

or Process Specification. 
Figure 2-7. Test Preparation Sheet
d. Document the need for procurement or fabrication of components

or parts.

Apollo Test and Operations will initiate a TPS for each item of work to be 

performed on Spacecraft and gromd support equipment. The task requirement 

will be entered and approved on this form prior to work being accomplished.

Ch completion of the work item(s) described, Quality Control will verify the 

quality performance of the task and an inspection verification stamp will 

be entered on the form. The TPS provides a means of maintaining a permanent 

record of work performed. The flow of TPS and TPMS Forms are illustrated in 

Figure 2-8.

2.7.1.2 Test Preparation Modification Sheet. The Test Preparation Modification

Sheet (TPMS) will authorise work which represents a correction, addition, or 

deletion to a TPS as originally released. Apollo Test and Operations will 

prepare aMPT S (see Figure 2-9) before the TPS is completed and closed out .

T he TPMS shall be indexed and filed as an integral part of the original TPS.

2.7.1.3 TPS & TPMS Index. This document will serve as an index of all Teat Preparation Sheets and Test Preparation Modification Sheets originated, and will

sequentially list each TPS and TPMS prior to work being accomplished.

NAA/S&ID and NASA Quality Control will indicate the completion of work by 

inserting an inspection acceptance stamp in an appropriate block of the index 

(see Figure 2-10).

2.7.1.4 Discrepancy R ecord. This form will be used to record discrepancies on spacecraft, ground support equipment, and spares. A Discrepancy Record (DR) will 

be initiated on items which cannot be returned to design configuration, or 

on discrepancies which invalidate a previously accepted test. The DR (see 

Figure 2-11) can be initiated by either S&ID Quality Control, Apollo Test 

and Operations, or NASA Quality Assurance and Inspection.
Figure 2-8. TPS & TPMS Flow Diagram
Figure 2-9. Test Preparation Modification Sheet
F igure 2-10. Test Preparation Sheet Index
Figure 2-11. Discrepancy Record
Disposition of a DR requires both S&ID and NASA Engineering approval. The 

flow of discrepancy records and discrepancy record squawk sheets are illustrated in Figure 2-12.

2.7.1.5 Discrepancy Record Squawk Sheet. A Discrepancy Record Squawk Sheet (DHSS) 

will be used to record minor discrepancies on spacecraft, ground support 

equipment, and spares. The DRSS (see Figure 2-13) will be initiated on items 

that can be returned to design configuration, and may be prepared by either 

S&ID or NASA Quality Control. Discrepancies will be entered sequencially in 

the DRSS and each squawk sheet shall be numbered. Corrective action on a 

DRSS will be determined by either AT&O Engineering or AT&O Shop Supervision.

2.7.1.6 Discrepancy Record Index. This index (see Figure 2-14) will be maintained by 

S&ID Quality Control, will sequentially list each DR written, and will 

accurately reflect DR status. Upon the satisfactory completion of a DR disposition action, the DR hard copy will be removed from the applicable TAIR 

Book. A buy-off will be effected by entry of the DR in the Discrepancy Record 

Index, and verif ied by an S&ID andAN S Quality Control inspection verification stamp.

2.7.1.7 Part Removal Record. Any part or component to be removed from Apollo end

items will be listed on the Part Removal Record, Form 79-Q (see Figure 2-13). 

In addition to part name, identification number and serial number, the reason 

for removal will be noted. Quality Control will verify each removal and replacement, and will also record the new part serial number and the original 

part number before the removal or replacement is accomplished. In conjunction 

with the entry on Form 79-Q, entries will also be made on the Installed Equipment Serialization Record and the Operational Time Change Items forms.
Figure 2-12. Discrepancy Record end Discrepancy Record Squawk Sheet Flow Diagram
Figure 2-13. Discrepancy Record Squawk Sheet
Figure 2-14. Discrepancy Record Index
Figure 2-15* Part Removal Record
2 .7 .1.8 Installed Equipment Serialization Record. The Installed Equipment 

Serialisation Record , Form 917-B (see Figure 2-16), will be used to record 

all part names, part numbers, serial n umbers, installation date and, if 

applicable, property tag numbers of installed parts, assemblies, components 

and m odules. Entries will be m ade by Quality Control with the assistance o f

Apollo Test and Operations, and verified by inspection. Appropriate entries 

w ill also be made in the Part Removal Record.

2.7.1.9 Operating Time and Discrepancy Record. This document, Form 917-A (see

Figures 2-17 and 2-18), will be used for accountability and traceability as 

well as to record operating time or cycles and discrepancies of functional 

time-significant items. Quality Control will make entries on this form , 

which will also be used in conjunction with the Operational Time Change

Items form .

2 .7.1.10 Operational Time Change Items. Quality Control will use the Operational Time 

Change Items, Forms 917-A (see Figure 2-19), to record the transfer of operating tim e/cycles from the Operational Time and Discrepancy Record when a 

functional assembly is absorbed into a higher assembly.

2 .7 .2 Materiel Condition Identification

Materiel condition status tags (AF Form 50 Series) are utilized in this program to identify the condition of individual items of ma teriel. Those tags 

are attached to an item at all times, except when the item is installed as 

part of a syste m , s u b s y s t e m ,assembly or (GSE . The following paragraphs describe the individual tags end their purpose.

2.7.2 .1 Serviceable, Incomplete Status & Hold Tag. The Serviceable, Incomplete

Status and Hold Tag, AF Form 50B (see Figure 2-20) is yellow. This tag is
Figure 2-16. Installed Equipment Serialization Record
Figure 2-17. Operating Time and Discrepancy Record (Sheet 1 of 2)
Figure 2-18. Operating Time and Discrepancy Record (Sheet 2 of 2)
Figure 2-19. Operational Time Change Items
Figure 2-20. Serviceable, Incomplete Status Hold Tag
a t t a c h e d to items that are ready for use in all respects, or that are ready 

for use except for changes to be incorporated or tests to be performed. 

Removal of this tag can only be made with the authority of Quality Control.

2.7.2.2 Reparable Tag. The Reparable Tag, AF Form 50D (see Figure 2-2l), is green. 

This tag is used to identify materiel that is not serviceable but that is 

reparable. Whenever an item is determined to be unserviceable by test, 

inspection, or other means, a determination will be made as to the reparability of the item. If determined to be reparable, a Reparable Tag will be 

attached to the item. The tag will remain attached until the item undergoes 

repair, or until other disposition has been determined.

2.7.2.3 Rejected or Condemned Tag. The Rejected or Condemned Tag, AF Form 50E (see 

iFgure 2-22), is red. This tag is attached to any item that is determined 

by inspection, test, or other means to be malfunctioning or unserviceable.

The tag will remain attached to an item until a determination has bsen made 

as to whether or not the item is reparable. If the item is determined to be 

reparable, the Rejected or Condemned Tag will be removed and replaced with a 

Reparable Tag.

2.8 SUPPORT MANUALS

In accordance with contractual requirements, Apollo support manuals shall be

developed by the contractor and its subcontractors to cover the Apollo spacecraft, ground support equipment and trainers. These manuals provide procedure 

information on end item checkout, operation and maintenance, as well as transportation and handling. Support manual management and development is fully 

described in the Apollo Support Plan, SID 62-702-1.
Figure 2-21. Reparable Tag
Figure 2-22. Rejected or Condemned Tag
BIBLIOGRAPHY

The bibliography presented below contains a brief description of the purpose and 

content of Apollo Program documents that have been referred to at one point or another 

in this Plan.

Apollo Program Plan (Confidential). SID 62-223

This document describes the effort involved in designing and developing 

the Apollo Command Module, Service Module, and Spacecraft Adapter, and 

integrating the Lunar Excursion Module (LEM) into the total spacecraft 

design. The Program Plan, is divided into three sections: The management 

plans, the technical development plan, and summaries of other pertinent 

plans. The purpose of this document is to present to the reader a comprehensive understanding of all aspects of the total program.

General Test Plan. SIB 62-109 Series

The General Test Plan is presented in five volumes, containing test plan 

research and development information for Project Apollo Spacecraft. Each of 

the volumes is revised quarterly by the System Integration Department of 

Apollo Engineering.

General Test Plan Research and Development for Project Apollo Spacecraft (Confidetal). SID62-109

This volume presents the overall test logic for Project Apollo and provides 

a summary of the testing activities relating to individual system, ground 

qualification, acceptance, and multiple systems. The summarized information, 

concerns objectives, procedures, schedules, and facilities.
General Test Plan Research, and Development for Project Apollo Spacecraft 

(Confidential). SID 62-109-2

This volume contains infor m ation on individual systems development, and 

detailed systems test plans for the Apollo service propulsion system, 

reaction control system, etc.

General Test Plan Research and Development for Project Apollo Spacecraft

(Confidential). SID 62-l09-3

This volume establishes and describes the ground qualification test program 

for Apollo Spacecraft and Ground Support Equipment (GSE).

General Test Plan Research and Development for Project Apollo Spacecraft 

SID 62-109-4

This volume describes the acceptance criteria for Apollo Spacecraft Equipm ent, and Ground Support Equipment (GSE), assembled at NAA/S&ID and its subcontractors.

General Test Plan Research and Development for Project Apollo Spacecraft 

(Confidential). SID 62-109-5

This volume presents detailed test plans for the multiple systems tests

described in Volume I, SID 62-109-1. The test location and the manner in

which. NAA/S&ID will accomplish the testing is specified.

Facilities Plan for Project Apollo Spacecraft (Confidential). SID 62-153

This document reflects S&ID's plan for the facilities required to fulfill 

Apollo Program objectives. The requirements are established on the basis 

of currently defined activities and schedules. Included in the Plan are 

S&ID Apollo facilities, major subcontractor facilities, and the NASA 

facilities involving S&ID technical support or engineering effort. This 

plan is prepared by the Apollo Facilities Department.
Apollo Quality Control Plan. SID 62-154—1

This document describes the methods and techniques used to implement quality 

control procedures for the Apollo Program. Quality Control activities are 

summarized for the overall program during all phases of Project Apollo.

This plan is updated as required by the Quality Engineering Department.

Apollo Quality Control Plan (Inspection and Test Control Point Flow Charts).

SID 62-l54-2

This document defines the general areas where quality inspection will be 

performed during the fabrication and assembly of Apollo Spacecraft and associated GSE. The specification used at each inspection point is also given.

The detail inspection requirements are delineated in the Fabrication Assembly 

Inspection Record (FAIR) book which is described in the Apollo Manufacturing 

Plan, SID 62-102. The Apollo Quality Control Plan (Inspection and Test 

Control Point Flow Charts), SID 62-154-2, is updated as required by the 

Quality Engineering Department.

Apollo Reliability Plan (Confidential). SID 62-205

This document provides an overall plan for implementation end administration 

of the Apollo Reliability Program. The plan also presents the organization, 

controls, and procedures to be employed by S&ID in meeting the requirements 

specified in the NAS 9-150 Contract. This document is revised as required by 

the Apollo Reliability Department.

Apollo Support Plan, SID 62-702-1

The purpose of this document is to define the Apollo materiel support requirements, as well as to describe the system and methods to be used by NAA/S&ID 

in satisfying the requirements. This plan covers all S& ID materiel support 

functions from provisioning through inventory disposition and provides detailed guide lines for support manuals management and development.
Apollo Training Plan (Confidential). SID 62-162

This document describes the Apollo training program, and the requirements 

for achieving an intagrated training effort for personnel participating in 

a mission. Apollo Logistics Training Department revises this plan as required.

Master Repair Schedule. SIP 63-903

This document identifies and lists all reparable items that pertain to the 

Apollo Spacecraft and Ground Support Equipment. It provides information upon 

which preliminary scheduling and manpower programming reparable item repair 

can be based. The Source Maintenance Recoverability (SMR) Code— a derivative 

of Maintenance Analysis— is entered adjacent to each item to show whether it 

is provisioned, where it can be removed and replaced, where it can be repaired, 

and who has disposition authority. The document also forecasts the cyclic 

repair of the items listed.
GLOSSARY OF TERMS

This glossary defines terms that relate to the Apollo Program in general. It 

is specifically applicable to the Apollo Support Plan, SID 62-702-1, the Apollo 

Maintenance Plan, SID 62-702-2, and will be applicable to all subsequently produced maintenance planning documentation.

ACCEPTANCE The act of an authorised representative, by 

which the customer approves specific services 

rendered, or acknowledges that certain specified 

articles are in conformity with the requirements 

of the contract.

ACCESSIBLTY The relative ease with which a component or an 

assembly can be approached to be repaired, replaced, or serviced.

ACCESSORY A mechanism or device employed to facilitate or 

increase the effective use of some other m echanism or piece of equipments.

ADJUSTMENT A means by which parts, as of a machine or device, 

are ad justed to one another to attain an operating standard peculiar to the unit.

AIRFRAME Assembled structural and aerodynamic components 

of a spacecraft or launch vehicle.

ARTICLE A unit of hardware, or any portion of the hardware, required by the contract.

ASSEMBLY A combination of parts or subassemblies that 

may be taken apart without destruction, which 

has no application or use of its own, but is 

essential for the completeness of a more complex 

item with which it is c o bmined. An assembly is 

an element of a component and performs functions 

necessary to the operation of the component as 

a whole.

ATTACHMENT A Supplementary device fastened to or mounted 

on a machine, apparatus, or other end item, so 

as to vary or extend its basic function.

BENCH M IANTENANCE EQUIPMENT 

(BME)

Equipment required to support subsystem and 

component testing. It is designed to provide 

the capability of isolating and defining malfunctions.
BOILERPLATE A simulated module for predevelopmental and

developmental tests leading to the design of 

the spacecraft.

BULK ITEMS Certain raw materials and semi-fabricated items

used in the manufacture of an article, including 

standard, commercial, and military hardware, 

e.g. , clips, clamps, fasteners, bolts, nuts, 

washers, hoses and lubricants.

CALIBRATE A method of comparing an instrument, device, or

dial with a standard to determine its accuracy, 

capacity or graduations, or devising a scale.

CALIBRATION TESTS Tests conducted to determine the input-to-output

characteristics of a measuring device, component, 

or assembly; these tests are also conducted to 

verify that the characteristics are within 

specified tolerances.

CHECKOUT A sequence of operational and calibrational tests

needed to determine the condition and status of 

a required operational function.

COMMAND MODULE The personnel and control vehicle in Apollo,

containing command and communication facilities 

and crew provisions.

COMMON AND STANDARD ITEMS Certain items of common ana standard use,

commercially available to industry, that adequately satisfy the requirements of the end 

article.

COMMON HARDWARE Certain items having multiple applications, e.g.,

nuts, bolts, screws, washers, pins, keys, grommets, 

rivets, etc.

COMMON TOOL Tools in general use that are applicable to a

variety of material, e.g. , screwdrivers, hammers

drill presses, etc.

COMPONENT A functional part of a system, subsystem, or replaceable package or module that is essential to 

their operational completeness. A component is 

a combination of units or parts that together say 

be functionally independent of, or an independent 

entity within, a complete operating module or 

subsystem, but which provide a self-contained 

function necessary for proper module, subsystem, 

and/or system operation.
CONFIGURATION The physical nature of an item; the physical

arrangement of components which comprise a 

spacecraft and its dimensions.

CONSUMABLE MATERIAL A type of item that is expanded through us e .

CONTRACT SCHEDULE The prime contract executed by the Government

and the prime contractor which, in addition to 

the terms and. conditions thereof, includes by 

reference or otherwise, specifications, drawings, 

exhibits, and other data necessary to its proper 

discharge.

CONTRACTOR The individual or concern that enters into a

prime contract with the Government, e .g .,

North American Aviation, Inc.

CONTRACTOR FURNISHED 

EQUIPMENT (CFE) 

An item of equipment provided by the contractor

under the terms of a contract.

CONTR0LLED ENVIRONMENT An environment in which factors such as humidity,

pressure, and temperature are under control.

CONTROLLED PARTS Parts, assemblies. or components which require

lot or serial number identification.

CORRECTI VE MAINTENANCE Maintenance performed on a nonscheduled basis

to restore equipment to a serviceable condition.

CRITICAL MATCHING ASSEMBLIES Assemblies that are specifically matched to a

particular spacecraft, GSE end item, trainer, 

or simulator.

CRITICAL M CATHING PARTS Parts that are specifically identified for use

on a particular spacecraft, GSE end item, trainer, 

or simulator.

CRITICAL MATCHING SPACECRAFT 

SUPPORT HARDWARE 

Assemblies that require specific fit to the

individual vehicle.

CUSTOMER The National Aeronautics and Space Administration

(NASA).

CUSTOMER WORK O RDER (CWO) An S&ID form which authorises the performance

of certain work such as the overhaul, repair, 

or modification of equipment. The CWO is used to 

identify and control item during the overhaul, 

repair, or modification cycle.

DELIVERABLE EQUIPMENT All manufactured hardware that is complete to

the degree required, and ready for delivery to 

any scheduled destination.
DIAGNOSIS The process of identifying a malfunction to the

level of component, assembly, or part at which 

the maintenance action will be taken.

DIRECT SUPPORT MATERIEL Proparty which may be incorporated into or

attached to an end item, or which may be consumed 

or expended in the performance of a contract. It 

includes raw and processed material, parts, 

assemblies, components, and sma11 tools and suppli es

which may be consumed in normal use in the performance of a contract.

DISPLAY Oscilloscopes, counters, dials, printers, lights,

indicators, scales, etc. , used to provide visual 

intelligence.

END ITEM A space system or any of its principal systems or

subsystem elements, e.g. , launch vehicle, spacecraft, ground support system, propulsion engine, 

or guidance system. Also, articles which will 

be delivered directly to a Government installation or provided as GFP to a contractor.

ENVIRONMENT The aggregate of the conditions and forces that

influence or effect an article and its performance 

throughout its service life.

EXPENDABLES A category o f materials that are not acceptable

upon issue.

FAILURE An occurrence, produced by sudden or gradual

deterioration, which causes equipment performance 

to deviate from specified limits.

FAILURE RATE The average number of failures occurring per unit

of time in a specified piece of equipment.

FAULT ISOLATION The process of determining the cause of failure

within a given system.

GOVERNMENT FURNISHED 

EQUIPMENT (GFE). 

Equipment furnished to the contractor by the

Government.

G0VERNMENT FURNISHED 

PROPERTY (GFP) 

All property in the possession of, or acquired

directly by the Government, and subsequently

delivered or otherwise made available to the 

contractor.
GROUND SUPPORT EQUIPMENT (GSE) All non-flight implements or devices required to

inspect, test, adjust, calibrate, appraise, gage, 

measure, repair, overhaul, assemble, disassemble, 

transport, safeguard, record, store, actuate, or 

otherwise perform a function in support of the 

spacecraft and boilerplate during (l) tests at 

factory subsequent to manufacturing completion,

(2) prelaunch, launch, end postlaunch operations 

at test sites, and (3) major development tests 

such as house spacecraft tests, propulsion teste, 

and environmental tests. This includes equipment 

required to support ground support equipment as 

defined herein.

HANDBOOKS In a general sense, any smal l book containing

specialised information or instructions.

HARDWARE The physical object, as distinguished from its

capability or function (actual engines, cases, 

pumps, the guidance system, or other components 

of the spacecraft or GSE). The term is also used 

in regard to a stage of development, e.g., the 

passage of a device or component from the design 

or planning stage into the hardware stage as the 

finished product.

IDENTIFICATION A term referring to a controlled serial or lot

number which relates the part, assembly, model, 

etc., to a particular lot of raw material, 

manufacturing process, manufacturer, manufacturing date, cure date, receiving date, purchased 

lot, historical data, assembly process, matched 

equipment, expiration date.

INDIRECT SUPPORT MATERIEL Equipment, machinery, structures, and consumable

material, used on a recurring basis for outfitting, 

maintaining or operating purposes. It also 

includes maintenance stock, tool crib supplies, 

stationery, office supplies, non-productive hardware, fuel, bottled water, dry ice, etc.

INSPECTION The examination, including testing, of contract

work, articles and services, to determine conformance to contract requirements.

INSPECTION AGENCY A Government agency, or an agency acting on

behalf of the Government, which determines that 

contracted work, articles and services, conform 

to technical requirements.
INSPECTION, FINAL An inspection which may occur either at the

contractor' s plant or at any other designated 

location. Its purpose is to verify compliance 

with applicable drawings and/or specifications, 

and to insure conformance with requirements of 

the contract.

INSPECTION, PRELIMINARY An inspection which is performed at the contractor's plant or a subcontractor's plant. Its 

purpose is to establish that the articles inspected 

are in conformity with requirements of the contract 

prior to shipment to the place of final inspection 

and acceptance.

INSPECTION, RECORD Final inspection and acceptance which is acknowledged in a Binding manner by an authorised 

representative of the customer.

INTEGRATED SYSTEM The physical end functional combination of two or

more systems required to complete an operational 

function, e.g., stabilization and control system, 

guidance and navigation system, reaction control 

system, and service propulsion system.

INTEGRATED SYSTEMS TEST A test of a vehicle or stage with two or more

systems involved.

INTERCHANGEABLE UNITS Assemblies, subassemblies, and replaceable parts

that can be substituted for one another without 

physical or electrical modification.

INTERCHANGEABILITY A property given a part so that it m ya be used

in more than one application.

INTERFACE In a rocket vehicle or other system, a common

boundary between one component and another; the 

junction point s or the point sw ithin or between 

systems or subsystems where matching or 

accommodation must be properly achieved in order 

to make their operation compatible with the 

successful operation of all other functional 

entities in the space vehicle and its ground 

support.

INTERIM RELEASE/EMERGENCY 

RELEASE 

An authorization to proceed with fabrication or

procurement of long lead time items prior to

the normal approval cycle.
LAUNCH COMMIT That point in time when the vehicle is actually

released.

LAUNCH ESCAPE SYSTEM (LES) A system providing for command module recovery

in case of mission abort after launch and prior 

to orbit, and consisting of the launch escape 

motor, launch escape tower, and tower jettison 

motor.

LOGISTICS SUPPORT The support given by an organisation to an

activity by means of which are furnished all, 

or any part of, its supplies, equipment maintenance, transportation, storage, or any other 

like service, so as to enable the activity to 

carry out its intended operation more expeditiously.

LOT SCHEDULE A schedule directing that an item be inspected,

crated, and readied for shipment prior to the 

lot number date, and shipped in the time period 

assigned.

LONG LEAD TIME ITEMS Items that cannot be delivered within a short

time span because of their complexity of design, 

complicated manufacturing processes, or limited 

production or procurement cycles.

LUNAR EXPEDIT ION MODULE (LEM ) The two-man vehicle which will land on the moon

after the Apollo spacecraft enters lunar orbit.

MAINTAINABILITY A quality of the combined features of material

design and installation that permits or enhances 

the accomplishment of maintenance by personnel 

of average skill. Material design parameters 

include such items as the operational and environmental conditions under which the maintenance 

functions will be performed. Also included are 

repairability and serviceability, which are 

functions of the ease with which maintenance 

activities may be performed to avert or correct 

malfunctions.

M AINTENANCE All actions required to retain mate riel in, or

restore it to, a serviceable condition. Its 

phases include servicing, repair, modification, 

overhaul, test, inspection, and condition determination.

MALFUNCTION A general term used to denote the inability of a

product to give satisfactory performance. It 

need not constitute a failure if readjustment 

of operator controls can restore an acceptable 

operating condition.
MATERIAL Ths substance or goods out of which an item is,

or can be, made.

MATERIEL Items of all kinds required for the equipment,

maintenance, operation, and support of activities.

MODIFICATION A change in the design of an item, effected in

order to correct a design deficiency, to facilitate production, or to improve operational 

effectiveness.

M ODULE A combination of components contained in one

package, or so arranged that together they are 

common to one mounting, which provides a complete 

function or functions to a system and/or subsystem 

in which it operates. (See command module, service 

module, lunar excursion module, etc.)

NASA'S DELEGATED REPRESENTATIVE A representative of NASA stationed at a supplier's

plant, or a representative of the inspection agency 

to whom quality assurance functions have been 

delegated,

NO-REPABL ITEM An item designed and procured with the intention

of disposing of it at failure rather than attempting repair.

0VERHAUL The rebuildin g or extensive repairing and reconditioning of an item of equipment which has deteriorated through testing or extensive use.

PACKAGING The cleaning, preservation, and packing in unit

quantities; interior cushioning and bracing; 

design and utilisation of interior and exterior 

containers; identification of contents of inner 

and outer containers; and leading.

PART The smallest subdivision of a system; an individual piece having an inherent functional capability 

but unable to function without the interaction of 

ether parte or forces, and ordinarily not subject 

to disassembly without destruction.

PECULIAR AND NON-STANDARD ITEMS Items peculiar to the equipment design of the contractor, subcontractor or supplier, for which no 

known common or standard item can be substituted, 

and for which design approval may not have been 

received.
PREVENTIVE MAINTENANCE The inspection, care, and servicing required to

maintain equipment and facilities in a serviceable 

condition.

PRIME CONTRACTOR North American Aviation, Inc., Space and Information Systems Division.

PROCEDURES The step-by-step manner in which any given task

is performed.

PROTOTYPE MODEL A model suitable for complete evaluation of

electrical and mechanical form, design, and performance. In its final form it employs approved 

parts and is completely representative of final 

equipment.

PURCHASED PARTS Articles manufactured by outside sources in conformance to S&ID drawings and identified by S&ID 

part numbers.

RECLAMATION The process of recovering required, serviceable,

and economical ly reparable components and materials.

RELEASE An approval to fabricate or procure items of

materiel support.

RELIABILITY The probability that a system, subsystem, component or part, will perform its required functions 

under defined conditions at a designated time and 

for a specified operating period. Dependability 

probability measure.

REPAIR The restoration of a system or equipment to a

satisfactory operating condition after malfunction, 

damage, or deterioration.

REPAIRABILITY The probability that when maintenance action

required by equipment malfunction is taken, (1) 

the system will be restored to a satisfactory 

operating condition in a given period of time 

with a given manpower expenditure; and (2) the 

equipment will remain in satisfactory operating 

condition over a specified period of time.

REPLACEABLE PACKAGE An item of equipment that say be mounted in or

removed from a spacecraft, checkout console, or 

the like, as a single package. A replaceable 

package or module is a combination of components 

contained in one package, or so arranged that 

together they are common to one mounting, which 

provides a complete function or functions for a 

system and/or subsystem in which it operates.
REPLACEABLE SERIALIZED UNIT The smallest serialised unit that can be replaced without soldering.

REPLACEMENT The substitution of one unit for another

functionally identical unit.

SERVICEABILITY A function of equipment design, configuration,

installation, and operation that indicates the 

degree to which maintenance requirements are 

minimised and simplified.

SERVICEABLE CONDITION That condition in which the article is considered suitable for carrying out the purpose 

for which it was assigned or authorized.

SERVICE LIFE The period of time or number of functional performances during which an item, installed in an 

operational system, will be expected to remain in 

a serviceable condition.

SERVICE MODULE The Apollo module containing propulsion equipment,

fuel, reaction control systems, and communications 

power. Used for thrust after booster separation, 

mid-course correction, lunar orbit, lunar orbit 

ejection, and earth return mid-course correction.

It is jettisoned prior to re-entry.

SERVICING The work performed at regular intervals, or under

a recognized system, to keep equipment operable. 

It includes cleaning, lubricating, adjusting, 

charging, and changing of filters, desiccators, etc.

SHELF LIFE That period of time during which an item can remain

in storage without having its operability affected.

SITE SUPPORT LIST A list of materiel items essential to the support

of a scheduled program at a field site.

SPACECRAFT In the Apollo Program, any component or combination

of components of the flight vehicle not part of 

the launch vehicle, e .g ., launch escape system, 

command module, service module, or adapter.

SPARE PART Any part, subassembly, or component kept in

reserve for the maintenance and repair of major 

items of equipment.

SPECIAL TOOLS Specially designed tools required to perform a

special function of maintenance, assembly, disassembly, etc.
SUBASSEMBLY A combination of parts comprising a definable 

entity of an assembly, a unit, or a component, 

which performs a function essential to the proper 

operation of the assembly, unit, or component.

SUBCONTRACTOR An organisation, company or manufacturer that is 

under contract to a prime contractor, and has 

been delegated the responsibility for design, 

manufacture, and support of a system.

SUBSYSTEM A major element in a system, comprised of a single 

module or combination of modules plus independent 

components that contribute to modular functions, 

all interconnected and interrelated within a 

system and performing a specific system function.

SUPPLIER A contractor or subcontractor actually performing the services or producing fee contract 

articles.

SUPPORT MANUAL A publication containing detailed information on 

technical procedures, including instructions on 

handling, inspection, storage, operation, maintenance, checkout, repair, modification, and overhaul of given equipment.

SYSTEM Any combination of complete operating equipment, 

comprised of a grouping or interconnection of 

subsystems or other functional entities, capable 

of performing a specific operational function or 

functions. Included are aerospace systems, support 

systems, command and control systems, and all 

associated material.

TEST ARTICLE An item that appears on a contractor, subcontractro 

or vendor drawing, and will be utilised as a 

subject of a test.

TEST SITE A facility established at a selected geographic 

location for conducting a specific operation or 

test.

TEST SUPPORT PART A part that is required for a unique application 

to accomplish a test function, and will not appear 

on a contractor, subcontractor, or supplier 

drawing as a functional part of that drawing.

TRACEABILITY A term which indicates the degree of yield from 

search for an item's history, application, use, 

and location.
TRADE-OFF Tbs procedure of trading a degrees of an attribute to gain a degree of another attribute, e.g., 

sacrificing a degree of performance to obtain a 

greater degree of reliability under certain conditions, or vice versa.

UNIT An assembly, or any combination of parts, subassemblies, and assemblies mounted together, 

normally capable of independent operation in a 

variety of situations.

The following definitions have been included as a means of further clarifying the 

depth and scope of the three levels of maintenance.

A-LEVEL MAINTENANCE All activity necessary to service, adjust, and

evaluate the readiness of a system, and which 

can bs performed with minimum delay. It includes 

maintenance which is within the limits of equipment configuration and within the verification 

capability of GSE common to systems and integrated 

systems checkout. Examples of system maintenance 

are as follows:

Electrical: Service, adjust, end checkout, or

fault isolate to a replaceable package level (fuel cell). Remove and 

install replaceable package and perform system verification.

Electronic: Service, adjust, and checkout, or

fault isolate to a replaceable package level (gyro accelerometer package). Remove and install replaceable 

package and perform system verification.

Mechanical: Service, adjust, and checkout, or

fault isolate to a replaceable package (oxygen control panel). Remove 

and install replaceable package and 

perform system verification.
B-LEVEL MAINTENANCE Replaceable package maintenance accomplished 

through replacement down to the replaceable 

serialized unit level. It includes maintenance 

which is within the verification capability of 

GSE common to replaceable package checkout.

Examples of replaceable package maintenance are 

as follows:

Electrical: Fault isolate to the replaceable serialized unit level 

(glycol pump, purge, valve). 

Service, adjust, or replace 

down to the serialized unit, 

and certify replaceable package.

Electronic: Fault isolate to the replaceable

serialized unit level (gyro preamplifier - ECA). Service, 

adjust, or replace down to replaceable serialized unit, and 

certify replaceable package.

Mechanical: Fault isolate to the replaceable 

serialized unit level (pump, 

purge, valve, pressure relief 

valve). Service, adjust, and 

replace down to replaceable unit 

and certify replaceable package.

C-LEVEL MAINTENANCE All maintenance activity associated with the Apollo 

Program which is beyond the A- and B-Levels, 

including total repair, modification and overhaul.

Electrical: Detailed disassembly to the 

part level (penetration of 

stack assembly, replacement 

of plates, connectors, etc.). 

Reassemble, adjust, calibrate, 

functionally check and 

certify.

Electronic: Detailed disassembly to the 

part level (diodes, resistors ,

capacitors, etched circuits, 

etc.). Replacement of 

defective parts or assemblies, 

and reassemble. Adjust, 

calibrate, functionally check 

and certify.