23Q0069_23FC012_JEFO_REDACTED.pdf

Service Bulletin – IGQSB040

IGQSB040 Issue 3 OFFICIAL Page 1

BMS-119-P1-D4 Rev 5

SERVICE BULLETIN – IGQSB040 Issue 3

DLF3B/MK59/SOPD DECOY LAUNCH TUBE ASSEMBLY

1 PLANNING INFORMATION

Effectivity:

The following items are affected by this Service Bulletin:

Supplier Part Number

Item NSN

E254-058/9 Launcher Gassing System N/A

This Service Bulletin gives information on action to be taken on next use of the subject equipment.

Reason:

IrvinGQ has been notified by the manufacturer of the Launcher Gassing System that is located externally to the Decoy Launch Tube Assembly (DLTA) that any system manufactured after 2014 may not perform as intended.

The Launcher Gassing System is required to expel the decoy from the launch tube on initiation via either remote launch or the manual push button.

There is a concern that a manufacturing error may result in slower gas flow into the launch tube that in the worst case would result in a misfire.

The risk of misfire is more likely via manual push button launch. This is minimised if the button is pushed and held until the decoy has exited the launch tube or a maximum of 15 seconds.

This update to the service bulletin details the method of inspection for a Launcher Gassing System to confirm if it is non-conforming. It also details the method of rectification for a non-conforming Launcher Gassing System.

The recommendation of push and hold for manual push button launches remains valid until inspection and rectification actions have confirmed the unit to be conforming.

IrvinGQ confirms that this Service Bulletin relates to the Operation (Reliability) of the Launcher Gassing System and that the reported non-conformance DOES NOT introduce any new Safety Risks (Risk of Injury or to Life), change any of the existing Safety Risks if the Decoy System is deployed, either remotely or manually.

IrvinGQ confirms that current mis-fire procedures are unaffected by the reported manufacturing error.

1 Export Controlled

2 UK

3 ML22a

DO NOT EXPORT/RE-EXPORT WITHOUT APPLICABLE

APPROVALS

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BMS-119-P1-D4 Rev 5

Approval:

This Service Bulletin has been reviewed by IrvinGQ Limited and the actions herein comply with the applicable Aviation Regulations and are APPROVED for the listed assemblies.

Author: A.Bates (Senior Project Engineer)

Reviewed by: J.James (Principal Engineer)

The technical accuracy of this Service Bulletin has been verified and is certified as correct.

Certified by: A.Jones (Design Assurance Signatory)

This document is electronically approved in accordance with the requirements of the IrvinGQ Ltd. accredited Business Management System and is valid without signatures; evidence is retained within the document record.

Effort Required:

The action to inspect and rectify as detailed within this Service Bulletin, Section 2, will take approximately 15-30 minutes per Decoy Gassing Systems to complete.

Material:

Not applicable

Tooling:

To carry out this procedure a Kit Box is provided.

The Kit Box contains all tooling required to inspect and rectify any non-conforming Launcher Gassing Systems. The kit is contained within a light weight, robust handheld case. On opening the case the following parts and tools are stored within specific cut-out locations:

Kit Box Identification

Number

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BMS-119-P1-D4 Rev 5

Item Ref

TOOL NAME TOOL No. IDENTIFICATION CHECK

A Tool, Extraction Ratchet)

T166041-001

1 off

B Housing, Detent Inspection

T165980-001

2 off Total

(1 Active)

(1 Spare)

C Assembly, Plunger T165989-001

D Extraction Tool T165978-001

E Insertion Tool, Set Screw

T165983-001

F Tweezers

G Inspection Mirror

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BMS-119-P1-D4 Rev 5

Item Ref

TOOL NAME TOOL No. IDENTIFICATION CHECK

H Loctite 242

(10 ml bottle)

I Scalpel 1 off

J Loctite Needle Applicator

7 off

K RTV Sealant 3145 1 off

L HyFlex Gloves 11-800 3 Pairs

M Test Block, Launcher Valve Head

T166009-001

The kit also contains the following spare parts.

Part

Ref

PART NAME

MOOG

P/No:

IDENTIFICATION CHECK

X Detent Pin B86666

Included as spares to replace lost or damaged parts

Y Compression Spring A87122

Included as spares to replace lost or damaged parts

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BMS-119-P1-D4 Rev 5

Part

Ref

PART NAME

MOOG

P/No:

IDENTIFICATION CHECK

Z Set Screw B36104

Must be used to replace discarded Set Screws

2 ACCOMPLISHMENT INSTRUCTIONS

Actions:

To reduce the likelihood of a misfire during Manual Push Button Firing of the Launcher Gassing System, it is recommended that the button is pushed and held until the decoy has exited the launch tube or a maximum of 15 seconds.

This recommendation of push and hold for manual push button launches remains valid until inspection and rectification actions have confirmed the unit to be conforming.

Complete the method detailed in this Service Bulletin to inspect and rectify all Launcher Gassing Systems.

Familiarisation and use of Inspection Equipment

Prior to conducting the inspection and check of a live Launcher Gassing System the user responsible for conducting the check is to complete the following familiarisation procedure using the provided Tool M (Test Block, Launcher Valve Head).

It is recommended that this section be carried out in an office or workshop environment prior to attempting the first ‘live’ inspection. It will assist in the identification, handling and determination of good and bad systems.

Select the following from the kit:

a. Tool B (Housing, Detent Inspection)

b. Tool C (Assembly, Plunger)

c. Tool M (Test Block, Launcher Valve Head)

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BMS-119-P1-D4 Rev 5

Screw Tool B (Housing, Detent Inspection) into Tool M (Test Block, Launcher Valve Head) at location identified as GOOD.

Ensure Tool B (Housing, Detent Inspection) is fully in contact with the top face of Tool M (Test Block, Launcher Valve Head).

There should be no gap between the two components.

Location:

GOOD

Location:

BAD

Tool M

GOOD

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BMS-119-P1-D4 Rev 5

Fit Tool C (Assembly, Plunger) into the central hole in Tool B (Housing, Detent Inspection).

With light finger pressure push Tool C (Assembly, Plunger) into Tool B (Housing, Detent Inspection)

Observe the top edge of Tool B (Housing, Detent Inspection).

The red section of Tool C (Assembly, Plunger) should not be visible above the top edge of Tool B (Housing, Detent Inspection).

Remove Tool C (Assembly, Plunger).

Unscrew Tool B (Housing, Detent Inspection) from Tool M (Test Block, Launcher Valve Head).

Refit Tool B (Housing, Detent Inspection) in Tool M (Test Block, Launcher Valve Head) at Location identified as BAD.

Ensure Tool B (Housing, Detent Inspection) is fully in contact with the top face of Tool M (Test Block, Launcher Valve Head).

There should be no gap between the two components.

BAD

Tool C

Location: GOOD

Good No Flange Visible

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BMS-119-P1-D4 Rev 5

Fit Tool C into the central hole in Tool B (Housing, Detent Inspection).

Observe the top edge Tool B (Housing, Detent Inspection). The red section of Tool C (Assembly, Plunger) should protrude above the top edge of Tool B (Housing, Detent Inspection).

Remove Tool C (Assembly, Plunger).

Unscrew Tool B (Housing, Detent Inspection) from Tool M (Test Block, Launcher Valve Head)

Place tools back in Kit Box.

Bad Red Flange Visible

Location: BAD

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BMS-119-P1-D4 Rev 5

Inspection/Check Procedure:

To confirm if the non-conformity is present carry out the following procedure.

Only authorised personnel who are familiar with this document can undertake the tasks contained within these instructions.

All observers must maintain a 1 metre minimum distance from the activity.

The following PPE is mandated for carrying out the task:

a. Safety Glasses (Not Supplied)

b. Ear Defenders (Not Supplied)

c. Gloves HyFlex 11-800 (Supplied within Kit Box; Item Ref L)

The following Safety Data Sheets are included:

a. Loctite 242 Blue Thread Locker Adhesive

b. Dowsil 3145 RTV Mil-A-46146 Sealant Grey

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BMS-119-P1-D4 Rev 5

SAFETY: ACTIONS BEFORE STARTING

a. This procedure will be conducted on a launcher gassing system that is assembled to the side of the launcher system, which is pneumatically charged with high pressure non-toxic gas.

b. The procedure requires working on the uncharged section of the gassing system valve, but caution should be taken due to working in close proximity to the charged section of the gassing system valve.

c. The risk of injury due to uncontrolled discharge is reduced to ALARP if the following actions are completed before the procedure begins and the PPE detailed in section 2.3.4 is worn.

Move the safe/launch handle to the safe position.

Ensure LCP Safety Switch is set to SAFE (Local Connection Panel).

Ensure both Forward and Aft DLTA-to- LCP cables are un-plugged from LCP.

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BMS-119-P1-D4 Rev 5

Check that the manual release button safety pin is fully located through the manual release button and secured with padlock.

Check that the manual release button cannot discharge the unit by pressing the button firmly. Nothing should happen.

Locate Detent Boss on unit surface facing launch tube.

Detent Boss Location

Launch Tube

Unit

Safety Pin

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BMS-119-P1-D4 Rev 5

OPEN THE KIT BOX.

a. Familiarise with tool and item locations. See image below.

b. Ensure parts correspond with Section 1.6 Kit Contents.

Spare Spare

Spare Spare

KIT

MG1007705-001

CONTAINING:

• Detent Pins (Item Ref X)

• Springs (Item Ref Y)

• Set Screws (Item Ref Z)

ITEM REF

J TOOL B TOOL C

Tool M Item Ref

I Item Ref

L Item Ref

K Item Ref

G

ITEM REF

F

ITEM REF

H

Tool E Tool D

TOOL A

S C

A L

P

L

T O

O L

E

X T

R A

C T

IO

N

R A

T C

H

T

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BMS-119-P1-D4 Rev 5

INSPECTION PROCESS – LIVE SYSTEM

REMOVE SET SCREW (PART REF Z)

a. Locate Set Screw (Part Ref Z) positioned in Detent Boss at the rear face (side facing launch tube) of the unit.

b. Using Tool A (Tool, Extraction Ratchet) insert the hex bit into the Set Screw (Part Ref Z) and turn anticlockwise to loosen.

c. Fully remove Set Screw (Part Ref Z) and discard it.

d. Note: Ensure the internal Spring (Part Ref Y) is not withdrawn with Set Screw (Part Ref Z).

INSERT TOOL B (HOUSING, DETENT INSPECTION) INTO UNIT BODY

a. Select Tool B (Housing, Detent Inspection) from the Kit Box.

b. Check thread is clean before inserting it into the unit (remove any debris with gloved finger only).

Tool B

Set Screw Location

Set

Screw

Tool A

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BMS-119-P1-D4 Rev 5

c. Insert Tool B (Housing, Detent Inspection) into the thread from where the Set Screw (Part Ref Z) was removed.

d. Note: Use left hand to provide light pressure to allow the thread to engage against the light spring pressure.

e. Turn Tool B (Housing, Detent Inspection) clockwise to tighten.

INFORMATION:

f. If resistance is felt during tightening, unscrew a ¼ turn and then continue tightening – repeat this action until Tool B (Housing, Detent Inspection) is fully screwed against the boss top face.

g. Ensure that Tool B (Housing, Detent Inspection) is screwed into the boss leaving no gap between the boss top face and Tool B (Housing, Detent Inspection) mounting face.

h. If a gap is found carefully remove Tool B (Housing, Detent Inspection). Check boss internal threads for dirt and contamination using mirror.

i. Clean threads and try screwing Tool B (Housing, Detent Inspection) in again.

j. Note: Ensure internal spring is not lost during any internal thread cleaning.

Tighten Clockwise

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INSERT TOOL C (ASSEMBLY, PLUNGER)

a. Select Tool C (Assembly, Plunger) from the Kit Box

b. Insert Tool C (Assembly, Plunger) in the hole in Tool B (Housing, Detent Inspection).

c. Gently push Tool C (Assembly, Plunger) in fully until it stops.

Tool C

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INSPECT FOR DEFECT

a. If the RED flange of Tool C (Assembly, Plunger) is not visible, the unit is GOOD - No defect.

b. Go to Section 2.3.18.

c. If the RED section of Tool C (Assembly, Plunger) is visible, unit is DEFECTIVE.

d. Continue to Section 2.4.

Good No Flange Visible

Bad Red Flange Visible

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BMS-119-P1-D4 Rev 5

REPLACE THE SET SCREW (PART REF Z)

a. Unscrew Tool B (Housing, Detent Inspection) from the unit and clean the threads.

b. Return to the Kit Box.

c. Inspect the detent bore with the Tool G (Inspection Mirror) to make sure the Detent Pin (Part Ref X) and Spring (Part Ref Y) are still present.

INFORMATION:

d. Use Tool F (Tweezers) if necessary to manipulate the Spring (Part Ref Y).

e. Locate and remove Loctite 242 (Item Ref H) bottle from Kit Box.

f. Remove bottle cap.

Using supplied Scalpel (Item ref I) remove the outer most tip only.

Cut Here

DO NOT Cut Here

The applicator fits on this diameter.

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g. Attach Loctite Needle Applicator (Item Ref J) to Loctite 242 (Item Ref H).

h. Push applicator until it is fully located against larger diameter shoulder.

i. Select a new Set Screw (Part Ref Z) from Kit Box.

j. Locate Tool E (Insertion Tool, Set Screw) from Kit Box.

k. Fit the Set Screw (Part Ref Z) female hex onto Tool E (Insertion Tool, Set Screw) male hex.

INFORMATION:

l. Ensure the orientation of the tool is maintained upwards to prevent the Set Screw (Part Ref Z) from falling out of its location.

m. Carefully squeeze Loctite 242 (Item Ref H) bottle to allow the Loctite to flow to the tip of the applicator.

Loctite Needle Applicator pushed fully against larger diameter shoulder

Tool E

Set Screw Part Ref Z

Tool E

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n. Apply Loctite 242 (Item Ref H) to the first two full threads of the Set Screw (Part Ref Z).

o. Using Tool E (Insertion Tool, Set Screw), locate the Set Screw (Part Ref Z) into its location within the unit’s detent boss.

Loctite 242 Item Ref H

Loctite 2 Full Threads

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p. Continue to screw in clockwise until Tool E (Insertion Tool, Set Screw) disengages from Set Screw (Part Ref Z).

q. Withdraw Tool E (Insertion Tool, Set Screw).

r. Return Tool E (Insertion Tool, Set Screw) to Kit Box.

s. Remove and discard Loctite Needle Applicator (Item Ref J) from Loctite 242 (Item Ref H).

t. Refit bottle cap to Loctite 242 (Item Ref H) bottle and return Loctite 242 (Item Ref H) bottle to Kit Box.

APPLICATION OF SEALANT

a. Locate and remove RTV Sealant (Item Ref K) from Kit Box.

INFORMATION:

b. Check the sealant use by date is in date (located on base of box and also stamped on tube base).

c. Remove tube cap and use reverse side of cap to pierce the foil seal (first time use only).

RTV Sealant 3145 (Item ref K)

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BMS-119-P1-D4 Rev 5

d. Gently squeeze the tube to allow sealant to flow to the tip of the tube.

e. Further squeeze whilst depositing a ‘globule’ of the sealant onto a gloved finger – see photo for approximate amount to be applied.

f. Use the gloved finger to apply the sealant over the boss face sufficient to ensure a watertight sealing.

g. Use Tool G (Inspection Mirror) to assist in locating and forming the sealant over the boss face.

h. Photo shows acceptable covering of RTV sealant over the boss face.

INFORMATION:

i. The sealant is workable for approximately 15 minutes and is tack free in approximately 2 hours.

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BMS-119-P1-D4 Rev 5

COMPLETION OF THE TASK

a. Return all items and parts to the Kit Box.

b. Ensure all tools and parts are accounted for.

c. Any Detent Pins and Springs that have been replaced with new must be disposed of to ensure remaining Detent Pins and Springs are pristine.

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BMS-119-P1-D4 Rev 5

Rectification Action(s):

Defect Correction

a. This is to be completed as a follow on procedure from section 2.3.17d.

b. Using finger pressure, firmly press Tool C (Assembly, Plunger) inwards until it overcomes any restriction and goes all the way in – RED flange not visible.

c. If the RED flange of Tool C (Assembly, Plunger) remains visible despite firm pressure being applied the unit will need to be returned to vendor for further inspection.

d. If Tool C (Assembly, Plunger) is in the “Good” position (RED flange not visible) then continue.

P re s s

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BMS-119-P1-D4 Rev 5

e. This operation is to ensure the Detent Pin (Part Ref X) inside the unit moves freely after completing section 2.4.1b.

f. Remove Tool C (Assembly, Plunger) leaving Tool B (Housing, Detent Inspection) in place as shown.

g. Return Tool C (Assembly, Plunger) to the Kit Box.

h. Select Tool D (Extraction Tool) from the Kit Box

i. For familiarisation, examine a spare Detent Pin (Part Ref X) from the Kit Box.

j. Note the small thread in the one end.

Information:

k. The Detent Pin (Part Ref X) inside the unit has this feature, the following instructions will use the small thread to check that the Detent Pin (Part Ref X) is free to move, proceed as follows.

Small Thread

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BMS-119-P1-D4 Rev 5

l. Insert Tool D (Extraction Tool) – threaded end first, into Tool B (Housing, Detent Inspection) and screw it into the small thread in the Detent Pin (Part Ref X).

m. Gently pull on Tool D (Extraction Tool) as though to pull it out of Tool B (Housing, Detent Inspection).

n. This should pull the Detent Pin (Part Ref X) which will move against a light spring pressure before coming to a stop.

o. Tool D (Extraction Tool) should move 3-5 mm. Movement should be free and the tool should return by spring force only.

p. If Tool D (Extraction Tool) movement is satisfactory remove Tool D (Extraction Tool) by unscrewing anti-clockwise and return it to the Kit Box.

Continue to Section 2.3.18.

If Tool D (Extraction Tool) is stuck within Tool B (Housing, Detent Inspection) and cannot be withdrawn, continue to Section 2.4.2.

NOTES:

q. If the Detent Pin (Part Ref X) / Tool D (Extraction Tool) does not move as described, then the unit will need to be returned to vendor for further inspection.

3 to 5 mm

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BMS-119-P1-D4 Rev 5

REMOVING TOOL D (EXTRACTION TOOL) IF IT CANNOT BE UNSCREWED

FROM DETENT PIN (PART Ref X)

a. If Tool D (Extraction Tool) cannot be unscrewed from the Detent Pin (Part Ref X) due to threads cross-threading etc, proceed as follows:

b. Unscrew Tool B (Housing, Detent Inspection) complete with Tool D (Extraction Tool) still inserted.

c. This will bring the Spring and the detent out too.

d. Spring and Detent Pin (Part Ref X) removed from unit body.

Detent Pin

Spring

Tool D

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e. Unscrew the Detent Pin (Part Ref X) from Tool D (Extraction Tool) and also remove Spring.

f. Check that the Detent Pin (Part Ref X) freely re-screws onto Tool D (Extraction Tool) thread.

g. If there is any doubt, discard the Detent Pin (Part Ref X) and select a new Detent Pin (Part Ref X) and new Tool D (Extraction Tool) from the Kit Box.

h. Should the spring become damaged or lost replace with spare Spring (Part Ref Y) from the Kit Box.

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BMS-119-P1-D4 Rev 5

REASSEMBLY OF THE PIN AND SPRING (PART REF Y) INTO THE UNIT

a. If for any reason the Spring (Part Ref Y) and Detent Pin (Part Ref X) have been removed from the unit body, they may be reassembled as follows.

b. Insert Tool D (Extraction Tool) through the hole in Tool B (Housing, Detent Inspection).

c. Place the Spring (Part Ref Y) over Tool D (Extraction Tool) (spring orientation is not important).

d. Screw the Detent Pin (Part Ref X) onto the thread of Tool D (Extraction Tool).

e. Check that the thread in Tool D (Extraction Tool) runs freely in the Detent Pin (Part Ref X).

f. The assembly should now look like this.

g. Screw the assembly back into the unit body.

Spring & Detent

Tool D

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BMS-119-P1-D4 Rev 5

h. Gently pull on Tool D (Extraction Tool) as though to pull it out of Tool B (Housing, Detent Inspection).

i. This should pull the Detent Pin (Part Ref X) which will move against a light spring pressure before coming to a stop.

j. Tool D (Extraction Tool) should move 3-5 mm. Movement should be free and the tool should return by spring force only.

k. If Tool D (Extraction Tool) movement is satisfactory remove Tool D (Extraction Tool) by unscrewing anti-clockwise and return it to the Kit Box.

Continue to Section 2.3.18.

NOTES:

l. If the Detent Pin (Part Ref X) / Tool D (Extraction Tool) does not move as described or is still stuck, then the unit will need to be returned to vendor for further inspection.

3 to 5 mm

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BMS-119-P1-D4 Rev 5

Reporting

Reports, queries or requests for information relating to this Service Bulletin may be made or sent to:

Quality Engineer IrvinGQ Limited Llangeinor Bridgend

CF32 8PL

MHopkins@irvingq.com mailto:PJones@irvingq.com

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BMS-119-P1-D4 Rev 5

Recording

Complete one Check Sheet for each system checked irrespective of whether it passes or fails.

Where possible please return copies of completed checksheets to IGQ for record of affected/non-affected units.

Checksheet

KIT BOX IDENTIFICATION NUMBER

(See Section 1.6.1 for Kit Box ID No. location)

Moog Launcher Model Number (MOD.)

Located on launcher nameplate - see example below E254-

Moog Launcher Serial Number (SER.)

Located on launcher nameplate - see example below

PASS FAIL

Indicate with a tick mark Indicate with a tick mark

OPERATOR NAME

Signature

Printed

DATE COMPLETED dd/mm/yy