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Airborne Systems 60410X Operator & Maintenance Instructions

Solr 100% oxygen mask
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OPERATOR & MAINTENANCE LEVEL 3
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 ® 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 MASKLEVEL 3 ® INTENTIONALLY BLANK 60410X...

  • Page 5: Reporting Errors And Recommending Improvements

    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. Mail your letter directly to: Airborne Systems, ATTN: Technical Publications, 5800 Magnolia Ave, Pennsauken, NJ.
  • Page 6 TM0063-2 SOLR 100% OXYGEN MASKLEVEL 3 ® INTENTIONALLY BLANK 60410X...

  • Page 7: Table Of Contents

    Table 6-3 SOLR® 100% Oxygen Mask Spare Parts ..............6-17 TOOLS LIST ............................6-23 Table 6-4 SOLR® 100% Oxygen Mask Tools 601711-3 ............... 6-23 EXPENDABLES ..........................6-25 Table 6-5 SOLR® 100% Oxygen Mask Expendables 607500-3 ............ 6-25 APPROVED FOR DISTRIBUTION ....................... A METRIC SYSTEM AND EQUIVALENTS .................... C 60410X...
  • Page 8 TM0063-2 SOLR 100% OXYGEN MASKLEVEL 3 ® INTENTIONALLY BLANK 60410X...

  • Page 9: Chapter 5 Level 3 Maintenance

    Exhaust Valve Disassembly 1. Place mask with the opening facing self. Figure 5-1 Mask Facing Self 2. Gently bend the microphone upwards, exposing the exhaust valve and regulator locking rings. Figure 5-2 Bend Microphone Up 60410X...
  • Page 10 4. Using the needle nose pliers, remove the locking wire from the exhaust valve assembly and discard. Figure 5-4 Remove Locking Wire 5. Remove exhaust cover by hand and set off to the side. 6. Remove the diaphragm by hand and discard. Figure 5-5 Remove Diaphragm 60410X...
  • Page 11 PLASTIC PICK. USE OF A METAL PICK CAN RESULT IN DAMAGE TO COMPONENTS. 9. With a plastic pick, remove the sealing ring from the exhaust valve body and discard. Figure 5-8 Remove Sealing Ring 10. Place exhaust housing to the side. 60410X...

  • Page 12: Regulator Disassembly

    3. Place the locking ring and locking washer to the side. 4. Remove dust cap from the quick disconnect and discard. 5. Using a 3/8 socket and driver remove the inlet quick disconnect. Figure 5-11 Remove Inlet Quick Disconnect 60410X...
  • Page 13 8. Using a 0.05 hex driver, remove the set screw from the regulator housing and discard. Figure 5-13 Remove Set Screw 9. Using the large spanner wheel and socket driver, remove the cap from the regulator body and set to the side. Figure 5-14 Remove Regulator Cap 60410X...
  • Page 14 Figure 5-16 Remove and Discard Diaphragm CAUTION THE ANTI-SUFFOCATION COVER IS UNDER SPRING PRESSURE. USE CAUTION WHEN REMOVING 12. Using the T8 torx driver, remove the two screws from the anti-suffocation cover and set to the side. Figure 5-17 Remove the Two Hex Screws 60410X...
  • Page 15 NOTE SLIGHT PRESSURE MAY BE NEEDED TO FREE THE LEVER 17. Using a hollow tip screwdriver, turn the crown clockwise while holding the regulator on its side to free the lever. Figure 5-20 Turn Crown Clockwise to Free Lever 60410X...
  • Page 16 Figure 5-21 Once Lever Drops Remove it By Hand 19. Remove the insert body by hand. Figure 5-22 Remove Insert Body by Hand 20. Remove the balanced seat by hand from the insert body and discard. Figure 5-23 Remove Balanced Seat from the Insert Body 60410X...
  • Page 17 22. Remove O-ring ID .364 from the insert body and discard it. Place the insert body off to the side. Figure 5-25 Remove and Discard O-Ring 23. Remove O-ring ID .228 from crown and discard it. Set the crown to the side. Figure 5-26 Remove and Discard O-Ring 60410X...
  • Page 18 25. Using a plastic pick, remove the sealing ring from the regulator body and discard it. Figure 5-28 Remove and Discard Sealing Ring 26. Using the 0.05 hex screwdriver, remove the set screw from the regulator body and set to the side. Figure 5-29 Remove Set Screw 5-10 60410X...
  • Page 19 27. Using compressed air, aim the nozzle at the set screw opening and blast with compressed air to remove the balancing chamber. Figure 5-30 Remove Balancing Chamber 28. Using a plastic pick, remove the two O-rings ID .228 from the balancing chamber and discard. 29. Place balancing chamber and the regulator body to the side. 60410X 5-11...
  • Page 20 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 3 ® INTENTIONALLY BLANK 5-12 60410X...

  • Page 21: Section Ii Oxygen Cleaning

    604172-X FACEPIECE,MW,SOLR MASK, CLEAN WITH MILD DETERGENT 604154-1 PORT, EXHAUST VALVE LEVEL 3 CLEANING 604156-0 COVER,EXHAUST LEVEL 3 CLEANING 604157-0 SEAL PLATE,EXHAUST VALVE LEVEL 3 CLEANING 604158-0 RING, LOCKING LEVEL 3 CLEANING 604159-0 WASHER, LOCKING LEVEL 3 CLEANING 60410X 5-13...
  • Page 22 LEVEL 3 CLEANING After all of the parts have been fully cleaned and fully dried, place them in a container such that they cannot be contaminated. Re-sealable poly bag and clean bins with a lid works well for this application. 5-14 60410X...

  • Page 23: Section Iii Level 3 Assembly

    1. Place the exhaust valve into the exhaust assembly and insert the stem through the hole in the center. Cut off excess stem. Figure 5-31 Cut Off Excess Stem 2. Ensure the exhaust valve is properly seated. Figure 5-32 Ensure Exhaust Valve is Properly Seated 60410X 5-15...
  • Page 24 4. Place the seal plate valve on the spring. Figure 5-34 Place Seal Plate Valve on Spring 5. Using the small spanner wheel with torque wrench, thread and secure the locking ring to 12-inch-lbs. Figure 5-35 Thread Locking Ring 5-16 60410X...
  • Page 25 8. Starting with the left side, insert the locking wire. Stop once it is 1/2 to 1-inch from the bend. Figure 5-37 Insert Locking Wire on the Left Side 9. Begin inserting the locking wire on the right side. Figure 5-38 Insert Locking Wire on the Right Side 60410X 5-17...
  • Page 26 Figure 5-40 Align the Notches with the Mask to the Exhaust Assembly 13. Insert exhaust assembly into the right side of the mask. 14. Place locking washer onto exhaust assembly with the raised edge facing down. Figure 5-41 Place Locking Washer with Raised Edge Facing Down onto Exhaust Assembly 5-18 60410X...
  • Page 27 SOLR 100% OXYGEN MASK LEVEL 3 TM0063-2 ® 15. Using the medium spanner wheel and torque wrench, thread the locking ring onto the exhaust assembly turning it clockwise, to 20-inch-lbs. Figure 5-42 Thread Locking Ring onto Exhaust Assembly 60410X 5-19...

  • Page 28: Regulator Assembly

    Figure 5-44 Place Balancing Chamber in Regulator Body NOTE USE LIGHT AMOUNT OF EVERSEAL ON SET SCREW 4. Using the 0.05 hex driver, thread the set screw into the regulator, ensuring its flush. Figure 5-45 Thread Set Screw into Regulator 5-20 60410X...
  • Page 29 7. Using the provided O-ring tool, place O-ring ID .364 on the insert body. Figure 5-48 Place O-Ring on Insert Body 8. Using the plastic assist tool, insert crown into insert body. Figure 5-49 Insert Crown into Insert Body 60410X 5-21...
  • Page 30 ENSURE THE BALANCED SEAT IS CLEAN AND FREE FROM DEFECTS BEFORE INSERTING. 10. Insert the balanced seat into the insert body. Figure 5-51 Insert Balanced Seat 11. Place the valve spring on the balanced seat. Figure 5-52 Place Valve Spring on Balanced Seat 5-22 60410X...
  • Page 31 Figure 5-54 Move Balanced Seat Forward NOTE USE LIGHT AMOUNT OF CHRISTO LUBE ON LEVER 14. Place the lever in cleared slot while rotating the insert body 90 degrees clockwise. Figure 5-55 Place Lever in Cleared Slot 60410X 5-23...
  • Page 32 17. Once the lever is fully raised, turn the crown clockwise and stop as soon as the lever begins to drop. Figure 5-57 Raise the Lever by Turning the Crown 18. Place the diaphragm in the regulator body, ensuring it is seated below the threads. Figure 5-58 Place Diaphragm in Regulator 5-24 60410X...
  • Page 33 20. Using the large spanner wheel and torque wrench, thread the regulator cover onto the regulator body to 12-inch-lbs. Figure 5-60 Thread Regulator Cover to the Regulator Body 21. Using a 0.05 hex drive, thread the set screw into the regulator body. Figure 5-61 Thread Set Screw 60410X 5-25...
  • Page 34 Figure 5-63 Thread Inlet Quick Disconnect into the Insert Body 24. Place O-ring ID .140 onto anti-suffocation piston by hand. 25. Insert the anti-suffocation piston in the regulator body. Ensure the depression in the piston is facing up. Figure 5-64 Insert Anti-Suffocation Piston 5-26 60410X...
  • Page 35 HOLD IT IN PLACE UNTIL IT IS PROPERLY SECURED TO THE REGULATOR. 29. Using the T8 torx drive with the torque wrench, thread the screws in the anti-suffocation cover, securing it to the regulator body, to 6-inch-lbs. Figure 5-67 Secure the Anti-Suffocation Cover to the Regulator Body 60410X 5-27...
  • Page 36 32. 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 quick disconnect, ± 1/8-inch. Figure 5-70 Ensure Microphone Wire is Even with the Quick Disconnect 5-28 60410X...
  • Page 37 Figure 5-72 Align the Notches on the Mask and the Regulator 35. Insert the regulator assembly into the left side of the mask. 36. Place locking washer onto regulator assembly with the raised edge facing down. Figure 5-73 Place Locking Washer with Raised Edge Facing Down onto Regulator 60410X 5-29...
  • Page 38 37. Using the medium spanner wheel, thread the locking ring onto the regulator turning it clockwise and torque to 20-inch-lbs. Figure 5-74 Thread Locking Ring onto Regulator 38. Connect the microphone wire to the microphone housing. Figure 5-75 Connect the Microphone Wire to the Housing 5-30 60410X...

  • Page 39: Chapter 6 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 40 Close V4 and V7, open V6 and V5 a minimum of 4 revolutions. Open V9. b. Using V3 adjust the flow to 100 SLPM on FM1. c. G4 must be less than 3-inches of water. d. Close V3, V5, V6, V9 60410X...

  • Page 41: Data Sheet

    45 ± 2 Below 3-Inches of Water @ 70 SLPM IN. H2O Below 3-Inches of Water @100 SLPM IN. H2O Exhalation Effort 45 ± 2 Below 3-Inches of Water @100 SLPM IN. H2O NOTE DATA CAN BE RECORDED AS PASS/FAIL. 60410X...
  • Page 42 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 3 ® INTENTIONALLY BLANK 60410X...

  • Page 43: Troubleshooting

    Remove and replace Defective Valve Spring the valve spring. Remove the quick disconnect, adjust the Inhalation Effort Above Misadjusted Lever Inhalation Effort crown out (counter 3” H2O Height clockwise) 1/8 of a turn, reinstall. Remove, clean, Stuck Lever/Seat Stem reassemble. 60410X...
  • Page 44 Exhalation Effort check valve Debris in the Exhaust Disassemble, clean, Valve reassemble. Plug Communications Wire Harness/Adapter Directly into the Malfunctioning Microphone, if this Microphone Cable Action Remedies Communication Does Communications Problem Replace Not Occur Microphone Wire Malfunctioning Replace Microphone Microphone 60410X...

  • Page 45: Section Ii Illustrated Parts Breakdown And Parts List

    This section lists and illustrates replacement parts for maintenance and in procurement, requisition or storage, issue and identification of new or reclaimed parts for the oxygen mask. The following explains the arrangement of parts identification. ILLUSTRATED PARTS BREAKDOWN Figure 6-1 100% Oxygen Mask Illustrated Parts Breakdown 60410X...
  • Page 46 MASK STRAP KIT, BLK (OPSCORE 2EA) 601261-0 MASK STRAP KIT, BLK, TEAM WENDY 604158-0 RING, LOCKING 604159-0 WASHER, LOCKING 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 60410X...
  • Page 47 SOLR 100% OXYGEN MASK LEVEL 3 TM0063-2 ® 604172-0 FACEPIECE,XSN,SOLR MASK 604172-1 FACEPIECE,SN,SOLR MASK 604172-2 FACEPIECE,MN,SOLR MASK 604172-3 FACEPIECE,MW,SOLR MASK 604172-4 FACEPIECE,LW,SOLR MASK 60410X...
  • Page 48 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 3 ® INTENTIONALLY BLANK 6-10 60410X...
  • Page 49 SOLR 100% OXYGEN MASK LEVEL 3 TM0063-2 ® Figure 6-2 100% Regulator Assembly Illustrated Parts Breakdown 60410X 6-11...
  • Page 50 COVER, VALVE, ANTI-SUFFOCATION, 100% O2 604165-0 INLET, QUICK DISCONNECT 604166-0 CROWN 604167-0 CHAMBER, BALANCING 604168-0 LEVER, MACHINED 604169-0 COVER, REGULATOR 604174-0 SPRING, VALVE,SOLR MASK 604175-0 SEAT,BALANCED,SOLR MASK 604176-0 GASKET,SOLR MASK 604177-1 RING,SEALING,SOLR MASK SPRING,ANTI-SUFFOCATION VALVE,100% 604182-0 O2,SOLR MASK 604183-0 DIAPHRAGM,SOLR MASK 6-12 60410X...
  • Page 51 SOLR 100% OXYGEN MASK LEVEL 3 TM0063-2 ® Figure 6-3 Exhaust Valve Assembly Illustrated Parts Breakdown 60410X 6-13...
  • Page 52 FIGURE & UNITS INDEX PART NUMBER DESCRIPTION NUMBER ASSY 604154-1 PORT,EXHAUST VALVE, ASSY 604156-0 COVER, EXHAUST 604157-0 PLATE, SEAL, EXHAUST VALVE 604177-1 RING,SEALING,SOLR MASK 604178-1 VALVE, EXHAUST, STEM, SOLR MASK 604179-0 SPRING,SOLR MASK 604181-1 WIRE,LOCKING,4IN 604185-0 CROWN, EXHAUST VALVE 6-14 60410X...
  • Page 53 100% OXYGEN MASK LEVEL 3 TM0063-2 ® Figure 6-4 Microphone Assembly Illustrated Parts Breakdown FIGURE & UNITS INDEX PART NUMBER DESCRIPTION NUMBER ASSY 601062-0 SCREW, SOLR MASK, #4-40, T8 TORX 604170-0 RETAINER, MICROPHONE WIRE 604173-0 MICROPHONE ASSEMBLY,M169A/AIC,SOLR MASK 604184-0 MICROPHONE WIRE,SOLR MASK 60410X 6-15...
  • Page 54 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 3 ® INTENTIONALLY BLANK 6-16 60410X...

  • Page 55: Spare Parts List

    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 MASK 604177-1 RING, SEALING, SOLR MASK 604152-0 MICROPHONE ASSEMBLY MICROPHONE ASSY 604173-0 M169A/AIC DILUTION MODULE, 604153-0 ASSEMBLY 60410X 6-17...
  • Page 56 UNIT PART ITEM NAME PHOTO NUMBER ISSUE 604159-0 WASHER, LOCKING 604158-0 RING, LOCKING MICROPHONE WIRE, SOLR 604184-0 MASK RETAINER, MICROPHONE 604170-0 WIRE SCREW, SOLR MASK, #4-40, 601062-0 T8 TORX VALVE, EXHAUST, STEM, 604178-1 SOLR MASK 604156-0 COVER, EXHAUST 6-18 60410X...
  • Page 57 PHOTO NUMBER ISSUE 604154-0 PORT, EXHAUST VALVE SEAL, PLATE, EXHAUST 604157-0 VALVE 604179-0 SPRING, EXHAUST VALVE 604160-0 BODY, REGULATOR 604161-0 INSERT, BODY COVER, VALVE, ANTI- 604164-0 SUFFOCATION SPRING, ANTI- 604182-0 SUFFOCATION PISTON, ANTI- 604163-0 SUFFOCATION 604162-0 PLATE, ANTI-SUFFOCATION 60410X 6-19...
  • Page 58 UNIT OF ITEM NAME PHOTO NUMBER ISSUE SEAT, BALANCED, SOLR 604175-0 MASK 604166-0 CROWN, SOLR MASK 604165-0 INLET, QUICK DISCONNECT LEVER, MACHINED, SOLR 604168-0 MASK COVER, REGULATOR, SOLR 604169-0 MASK SPRING, VALVE, SOLR 604174-0 MASK 604176-0 WASHER, SOLR MASK 6-20 60410X...
  • Page 59 604183-0 DIAPHRAGM, SOLR MASK 604184-0 CROWN, EXHAUST VALVE SCREW, SOLR MASK 601260-0 STRAPS BAYONET, OFFSET, LEFT 601262-0 AND RIGHT MASK, STRAP KIT, BLK, 601261-0 TEAM WINDY MASK, STRAP KIT, TAN, 601248-0 OPSCORE MASK, STRAP KIT, BLK, 601248-1 OPSCORE 60410X 6-21...
  • Page 60 O-RING ID. 140 601017-2 O-RING ID. 228 601017-5 O-RING ID .364 HARDSHELL ASSEMBLY, SOLR MASK -0: XSN 604171-X -1: SN -2: MN -3: MW -4: LW FACEPIECE, SOLR MASK -0: XSN -1: SN 604172-X -2: MN -3: MW -4: LW 6-22 60410X...

  • Page 61: Tools List

    DRIVE BIT, POWER TO DRIVE, 1/4" 601762-0 DRIVE 2” BIT, POWER TO TORX T8, 601762-3 2” BIT POWER TO #2 PHILLIPS 601762-2 2” TORQUE DRIVER, 6-30 601757-0 INCH LBS, CLICK 601747-0 TORX DRIVER T8 601751-5 HEX DRIVER, .05” 60410X 6-23...
  • Page 62 SCREWDRIVER, #0, 601752-4 PHILLIPS PRECISION SCREWDRIVER, #2 601752-3 PHILLIPS, STUBBY SCREWDRIVER, 3/16” 601753-3 HOLLOW TIP PLIERS, NEEDLE NOSE, 6 601744-0 3/4" 601743-0 TWEEZERS, SS, 3” SOCKET, 3/8 DEEPWELL, 601746-0 1/4” DRIVE 601773-0 O-RING PICK, PLASTIC 601751-1 HEX DRIVER, 5/64” 6-24 60410X...

  • Page 63: Expendables

    CHRITO LUBE 607511-0 PTFE TAPE CROSS CHECK, TORQUE 607508-0 SEAL BOTTLE, SQUEEZE, W/ 607509-0 NOZZLE, BLUE LEAKTECH, SOAPY 607510-0 WATER, 1 GALLON 607109-1 EVERSEAL, 4 OZ BOTTLE BUBBLE-O METER FLUID, 8 607109-1 WIPES, CLEANROOM, 100 607507-0 PK, 12” x12” 60410X 6-25...
  • Page 64 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 3 ® PART UNIT OF ITEM NAME PHOTO NUMBER ISSUE SOLR PORTABLE TEST 607200-0 STAND 6-26 60410X...

  • Page 65: 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 66 TM0063-2 SOLR 100% OXYGEN MASK LEVEL 3 ® INTENTIONALLY BLANK 60410X...

  • Page 67: Metric System And Equivalents

    0.454 grams ounces 0.035 short tons metric tons 0.907 kilograms pounds 2.205 pound-feet newton-meters 1.356 metric tons short tons 1.102 pound-inches newton-meters 0.113 Temperature (Exact) To Change Fahrenheit Temperature To Celsius Temperature Subtract 32 than Multiply 0.556 60410X...

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