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Airborne Systems SOLR 60410X Operator & Maintenance Instructions

100% oxygen mask
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OPERATOR & MAINTENANCE LEVEL 2
SOLR
WARNING: This document may contain technical data whose export is restricted by the Arms Export Control Act (Title 22,
U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of
these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.
DESTRUCTION NOTICE: Destroy by any method that would prevent Disclosure of content or reconstructions of the document.
ISSUE 2
INSTRUCTIONS
100% O
®
XYGEN
60410X
TM0063
M
ASK
15 JANUARY 2020

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  • Page 1 TM0063 OPERATOR & MAINTENANCE LEVEL 2 INSTRUCTIONS SOLR 100% O ® XYGEN 60410X WARNING: This document may contain technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties.
  • Page 2 © COPYRIGHT NOTICE This SOLR ® 100% Oxygen Mask technical manual is protected by U.S. and International copyright laws. Reproduction and distribution of the information within this technical manual without written permission from Airborne Systems North America Inc. is prohibited.

  • Page 3: Record Of Changes

    Some revisions may not require a new manual. Contact your Airborne Systems sales associate for assistance in getting an updated technical manual. CHANGE...
  • Page 4 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® INTENTIONALLY BLANK 60410X...

  • Page 5: Reporting Errors And Recommending Improvements

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® OPERATOR & MAINTENANCE LEVEL 2 INSTRUCTIONS SOLR ® 100% OXYGEN MASK 60410X REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures please let us know.
  • Page 6 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® INTENTIONALLY BLANK 60410X...

  • Page 7: Table Of Contents

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® TABLE OF CONTENTS RECORD OF CHANGES ........................... I REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS ...........III CHAPTER 3 LEVEL 2 MAINTENANCE .................... 3-1 SECTION I LEVEL 2 MAINTENANCE OF THE SOLR ® 100% OXYGEN MASK ..... 3-1 DISASSEMBLY/REPLACEMENT OF OXYGEN COMPONENTS ..........
  • Page 8 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® INTENTIONALLY BLANK 60410X...

  • Page 9: Chapter 3 Level 2 Maintenance

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® CHAPTER 3 LEVEL 2 MAINTENANCE SECTION I LEVEL 2 MAINTENANCE OF THE SOLR 100% OXYGEN MASK ® DISASSEMBLY/REPLACEMENT OF OXYGEN COMPONENTS Repair of component parts is limited to replacement of assemblies. • Replace all assemblies that exhibit excessive wear such as;...
  • Page 10 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® 2. Remove the exhaust cover by hand and place in a clean and dry area. 3. Remove the damaged exhaust valve by hand and discard. Figure 3-2 Discard Damaged Exhaust Valve NOTE DO NOT CUT THE STEM COMPLETELY OFF AND DO NOT CUT BELOW THE RED LINE (FIGURE 3-3).
  • Page 11 SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® 6. Place exhaust cover on exhaust port. NOTE ENSURE THE HOLES ON THE EXHAUST COVER ARE FACING UPWARD. 7. Bend the locking wire in half. 8. Starting with the left side, insert new locking wire. Stop once it’s 1/2 to 1-inch from the bend. 9.

  • Page 12: Removal Of Exhaust Assembly

    TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® Removal of Exhaust Assembly 1. Place mask with the opening facing self. Figure 3-6 Mask Facing Self 2. Gently bend the microphone upwards, exposing the exhaust and regulator locking rings. Figure 3-7 Bend Microphone Up 3.
  • Page 13 SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® ® 4. Remove the locking ring, locking washer and exhalation assembly from the SOLR mask and place the parts in a container. Figure 3-9 Locking Ring, Locking Washer and Exailation Assembly NOTE ENSURE SEALING RING IS IN PLACE 60410X...

  • Page 14: Removal Of Regulator Assembly

    TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® Removal of Regulator Assembly 1. Press the red button on the microphone housing to disconnect the microphone. Figure 3-10 Disconnect the Microphone 2. Flip the mask over and using the medium spanner wheel, remove the regulator valve assembly by turning the locking ring counter clockwise.
  • Page 15 SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® 4. Using a .T8 torx driver, remove the microphone cable from the regulator. Figure 3-13 Remove Microphone Cable from Regulator 60410X...

  • Page 16: Removal Of Microphone Assembly

    TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® Removal of Microphone Assembly 1. Using a #0 phillips screwdriver, remove the microphone housing by turning it counter clockwise. Figure 3-14 Remove Microphone Assembly 2. Once the microphone housing is removed, proceed to remove the microphone and microphone gasket by hand.

  • Page 17: Removal Of Face Straps And Hard Shell

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® Removal of Face Straps and Hard Shell 1. Using a #2 phillips screwdriver, remove the screws from the adjustment straps by turning it counter clockwise. Figure 3-16 Remove Face Straps 2. Once the adjustment straps are removed, place them in a container. Figure 3-17 Adjustment Straps 3.
  • Page 18 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® INTENTIONALLY BLANK 3-10 60410X...

  • Page 19: Section Ii Reassemble Solr ® 100% Oxygen Mask

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® SECTION II REASSEMBLE SOLR 100% OXYGEN MASK ® REASSEMBLY OF THE SOLR ® 100% OXYGEN MASK Adjustment Strap and Microphone Assembly NOTE THE OXYGEN MASK STRAPS CAN BE REPLACED/REMOVED WITHOUT FULL DISASSEMBLY OF MASK. 1.
  • Page 20 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® NOTE ENSURE THE CORRECT ORIENTATION OF THE MICROPHONE, WITH THE WIRE BENDING UPWARD (FIGURE 3-22). Figure 3-21 Ensure Correct Orientation of Microphone Wire 3. Hold the hard shell against the soft shell and insert the microphone and align the prongs with the two center holes in the mask.

  • Page 21: Regulator Assembly

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® Regulator Assembly 1. Using the T8 torx driver, connect the microphone cable to the regulator. Adjust the microphone wire until the female end of the microphone wire is even with the end of the inlet valve, ± 1/8-inch Figure 3-24 Ensure Microphone Wire is Even with the Inlet Valve 2.
  • Page 22 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® 4. Insert the regulator assembly into the left side of the mask. 5. Place locking washer onto regulator assembly with the raised edge facing down. Figure 3-27 Place Locking Washer with Raised Edge Facing Down onto Regulator 6.

  • Page 23: Exhaust Assembly

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® Exhaust Assembly 1. Align the two notches on the right side of the mask with the two indents on the exhaust assembly. Ensure sealing ring is in place. Figure 3-30 Align the Notches with the Mask to the Exhaust Assembly 2.
  • Page 24 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® INTENTIONALLY BLANK 3-16 60410X...

  • Page 25: Chapter 4 Troubleshooting And Parts List

    Functions check must be performed prior to initial use, after any level 2 service, and continuing at every 6 months. Functions check must be performed on a calibrated Airborne Systems Test Stand. Refer to the Test Stand manual for proper set up and calibration. Start each test with the oxygen cylinder valve open, V1 open, and the regulator RI set at 0 PSI on G2.
  • Page 26 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® 4. Inhalation effort pre breathing a. Open V10 b. Open V5 to get a flow of 20 SLPM on FM1 c. G5 must read less than 3-inches of water. d. If the input pressure falls out of 70 ± 2 PSI use the regulator RI to readjust. e.

  • Page 27: Data Sheet

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® Data Sheet Used for reference only. Table 4-1 Data Sheet REQUIRMENTS VALUE INPUT TEST Anti-Suffocation Test Valve Closed Below 30 PSI Free Flow Test 80 PSI No Audible Leak Pass/Fail Mask Interface Seal 70 ±...
  • Page 28 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® INTENTIONALLY BLANK 60410X...

  • Page 29: Troubleshooting

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® TROUBLESHOOTING Table 4-2 Troubleshooting TEST TROUBLE PROBABLE CAUSE REMEDY Demand Valve Does Debris on Replace Regulator Free Flow Not Close Seat/Damaged Seat Assembly Bad Position on Reset Mask Interface Mask Interface is Inspect/Replace Foam Damaged Remove all Assemblies,...
  • Page 30 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® INTENTIONALLY BLANK 60410X...

  • Page 31: Section Ii Illustrated Parts Breakdown And Parts List

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-1 ® SECTION II ILLUSTRATED PARTS BREAKDOWN AND PARTS LIST This section lists and illustrates replacement parts for maintenance and procurement, requisition or storage, issue and identification of new or reclaimed parts for the oxygen mask. The following explains the arrangement of parts identification.
  • Page 32 TM0063-1 SOLR 100% OXYGEN MASK LEVEL 2 ® FIGURE & INDEX PART UNITS PER DESCRIPTION NUMBER NUMBER ASSY 604100-0 MASK, SOLR, 100%, OPSCORE, XSN 604100-1 MASK, SOLR, 100%, OPSCORE, SN 604100-2 MASK, SOLR, 100%, OPSCORE, MN 604100-3 MASK, SOLR, 100%, OPSCORE, MW 604100-4 MASK, SOLR, 100%, OPSCORE, LW 604101-0...
  • Page 33 SOLR 100% OXYGEN MASK LEVEL 2 TM0063-1 ® FIGURE & INDEX PART UNITS PER DESCRIPTION NUMBER NUMBER ASSY 604171-0 HARDSHELL ASSEMBLY, XSN,SOLR MASK 604171-1 HARDSHELL ASSEMBLY, SN,SOLR MASK 604171-2 HARDSHELL ASSEMBLY, MN,SOLR MASK 604171-3 HARDSHELL ASSEMBLY, MW,SOLR MASK 604171-4 HARDSHELL ASSEMBLY, LW,SOLR MASK 604172-0 FACEPIECE,XSN,SOLR MASK 604172-1...
  • Page 34 TM0063-1 SOLR 100% OXYGEN MASK LEVEL 2 ® Figure 4-2 Microphone Assembly Illustrated Parts Breakdown FIGURE & UNITS INDEX PART NUMBER DESCRIPTION NUMBER ASSY 601062-0 SCREW, SOLR MASK, #4-40, T8 TORX 607170-0 RETAINER, MICROPHONE WIRE 604173-0 MICROPHONE ASSEMBLY,M169A/AIC,SOLR MASK 604184-0 MICROPHONE WIRE,SOLR MASK 4-10 60410X...

  • Page 35: Spare Parts List

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-1 ® SPARE PARTS LIST Table 4-3 SOLR ® 100% Oxygen Mask Spare Parts UNIT PART ITEM NAME PHOTO NUMBER ISSUE 1/4-16 601359-0 DUST CAP, MALE, MASK, SC 1/4-16 604150-0 VALVE, EXHAUST ASSY 604151-0 REGULATOR ASSEMBLY WIRE, LOCKING, 4IN, SOLR 604181-1...
  • Page 36 TM0063-1 SOLR 100% OXYGEN MASK LEVEL 2 ® 604156-0 COVER, EXHAUST 604159-0 WASHER, LOCKING 604158-0 RING, LOCKING MICROPHONE WIRE, SOLR 604184-0 MASK RETAINER, MICROPHONE 607170-0 WIRE SCREW, SOLR MASK, #4-40, 601062-0 T8 TORX VALVE, EXHAUST, STEM, 604178-1 SOLR MASK SCREW, SOLR MASK 601260-0 STRAPS 4-12...
  • Page 37 SOLR 100% OXYGEN MASK LEVEL 2 TM0063-1 ® BAYONET, OFFSET, LEFT 601262-0 AND RIGHT MASK, STRAP KIT, BLK, 601261-0 TEAM WENDY MASK, STRAP KIT, TAN, 601248-0 OPSCORE MASK, STRAP KIT, BLK, 601248-1 OPSCORE HARDSHELL ASSEMBLY, SOLR MASK -0: XSN 604171-X -1: SN -2: MN -3: MW...
  • Page 38 TM0063-1 SOLR 100% OXYGEN MASK LEVEL 2 ® INTENTIONALLY BLANK 4-14 60410X...

  • Page 39: Tools List

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-1 ® TOOLS LIST Table 4-4 SOLR ® 100% Oxygen Mask Tools 601711-2 PART UNIT OF ITEM NAME PHOTO NUMBER ISSUE SPANNER WHEEL, SOLR, 601767-1 MASK SOCKET DRIVER, 1/4-INCH 601758-0 DRIVE BIT, POWER TO DRIVE, 1/4" 601762-0 DRIVE 2”...
  • Page 40 TM0063-1 SOLR 100% OXYGEN MASK LEVEL 2 ® PART UNIT OF ITEM NAME PHOTO NUMBER ISSUE 601751-5 HEX DRIVER, .05” 601751-1 HEX DRIVER, 5/64” SCREWDRIVER, 1/4" FLAT 601753-2 TIP, STUBBY SOLR PORTABLE TEST 607200-0 STAND 4-16 60410X...

  • Page 41: Approved For Distribution

    60410X ISSUE 2 15 JANUARY 2020 Approved For Distribution: Prepared By: Oliver K. Frazeur Technical Writer Assistant Airborne Systems - NJ Reviewed By: Yannick Bonnemaiso 02 Systems R&D Manager Airborne Systems - NJ Approved By: JC Berland Chief Technical Officer...
  • Page 42 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 2 ® INTENTIONALLY BLANK 60410X...

  • Page 43: Metric System And Equivalents

    SOLR 100% OXYGEN MASK LEVEL 2 TM0063-2 ® Metric System and Equivalents Linear Measure Liquid Measure 1 centimeter = 10 millimeters = .39 inches 1 centiliter = 10 milliliters = .34 fl. ounce 1 decimeter = 10 centimeters = 3.94 inches 1 deciliter = 10 centiliters = 3.38 fl.

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