Airborne Systems SOLR 60410X Manual

TM0063
ISSUE 2 15 JANUARY 2020
OPERATOR & MAINTENANCE LEVEL 3
INSTRUCTIONS
SOLR®100% OXYGEN MASK
60410X
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© 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.

SOLR®100% OXYGEN MASK LEVEL 3 TM0063-2
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RECORD OF CHANGES
Go to https://airborne-sys.com/riggers-corner/ see if your technical manual is the most current by searching
for the manual and reviewing the record of changes page. Some revisions may not require a new manual.
Contact your Airborne Systems sales associate for assistance in getting an updated technical manual.
CHANGE
NO.
DATE TITLE OR BRIEF DESCRIPTION ENTERED BY
Issue 1 14 June 2018
SOLR® 100% Oxygen Mask Operator &
Maintenance Level 3 Instructions
Oliver K. Frazeur
Issue 2 15 January 2020
Added PTS to parts list. Added 604108-X to
configurations
Oliver K. Frazeur

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SOLR®100% OXYGEN MASK LEVEL 3 TM0063-2
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OPERATOR & MAINTENANCE LEVEL 3
INSTRUCTIONS
FOR
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.
08109. You may
also send in your recommended changes via electronic mail or by
fax. Our fax number is [phone]. Our e-mail address is tech.pubs@airborne-
sys.com. A reply will be furnished to you.

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SOLR®100% OXYGEN MASK LEVEL 3 TM0063-2
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TABLE OF CONTENTS
RECORD OF CHANGES...........................................................................................................................I
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS...........................................III
CHAPTER 5 LEVEL 3 MAINTENANCE ............................................................................................ 5-1
SECTION I LEVEL 3 MAINTANENCE OF THE SOLR® 100% OXYGEN MASK....................5-1
SOLR® 100% OXYGEN MASK DISASSEMBLY ............................................................................. 5-1
Exhaust Valve Disassembly............................................................................................................... 5-1
Regulator Disassembly....................................................................................................................... 5-4
SECTION II OXYGEN CLEANING ................................................................................................. 5-13
SOLR® 100% OXYGEN CLEANING............................................................................................... 5-13
Oxygen Cleaning.............................................................................................................................. 5-13
Table 5-1 Oxygen Cleaning ............................................................................................................ 5-13
SECTION III LEVEL 3 ASSEMBLY ................................................................................................ 5-15
SOLR® 100% OXYGEN MASK ASSEMBLY ................................................................................. 5-15
Exhaust Assembly............................................................................................................................ 5-15
Regulator Assembly ......................................................................................................................... 5-20
CHAPTER 6 TROUBLESHOOTING AND PARTS LIST ................................................................. 6-1
SECTION I FUNCTIONS CHECK AND TROUBLESHOOTING OF THE SOLR® 100%
OXYGEN MASK ..................................................................................................................................... 6-1
TEST ...................................................................................................................................................... 6-1
Functions Check................................................................................................................................. 6-1
Functions Check Procedure................................................................................................................ 6-1
Data Sheet .......................................................................................................................................... 6-3
Table 6-1 Data Sheet......................................................................................................................... 6-3
TROUBLESHOOTING......................................................................................................................... 6-5
Table 6-2 Troubleshooting................................................................................................................ 6-5
SECTION II ILLUSTRATED PARTS BREAKDOWN AND PARTS LIST ...................................6-7
ILLUSTRATED PARTS BREAKDOWN ............................................................................................ 6-7
SPARE PARTS LIST .......................................................................................................................... 6-17
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

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SOLR®100% OXYGEN MASK LEVEL 3 TM0063-2
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CHAPTER 5
LEVEL 3 MAINTENANCE
SECTION I LEVEL 3 MAINTANENCE OF THE SOLR®100% OXYGEN MASK
SOLR®100% OXYGEN MASK DISASSEMBLY
Full disassembly, inspection of all parts, cleaning of all hard parts, and replacement of all overhaul kit parts
must happen every 5 years. Level 3 maintenance and repair may not require full disassembly.
Before disassembling the SOLR®mask, ensure you have a clean and clear work space. Wipe all work
surfaces down with Isopropyl Alcohol. All parts to be discarded will be listed in the following instruction.
All parts not discarded must be handled and stored in a method as not to damage the parts. Suggestion are
work trays, part bins, and for smaller parts, re-sealable poly bags.
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

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3. Using the 1/4-inch driver with medium spanner wheel, remove exhaust assembly by turning the locking
ring counter clockwise.
Figure 5-3 Remove Exhaust Locking Ring
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

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7. Using the small spanner wheel and socket driver, remove the locking ring from the exhaust valve
assembly.
Figure 5-6 Remove Locking Ring from the Exhaust Valve Assembly
8. Set aside the locking ring, exhaust valve stem, and exhaust valve spring.
Figure 5-7 Set Aside Locking Ring, Valve Stem and Valve Spring
CAUTION
REMOVAL OF GASKETS AND O-RINGS SHOULD BE DONE WITH A
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.

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Regulator Disassembly
1. Press the red button on the microphone housing to disconnect the microphone.
Figure 5-9 Disconnect the Microphone
2. Using the medium spanner wheel, remove the regulator valve assembly by turning the locking ring
counter clockwise.
Figure 5-10 Remove Regulator Locking Ring
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

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6. Using a plastic pick, remove O-ring ID .228 form the inlet quick disconnect.
Figure 5-12 Discard O-Ring from Inlet Quick Disconnect
7. Place the inlet quick disconnect off to the side.
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

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10. Remove washer by hand and discard.
Figure 5-15 Remove and Discard Washer
11. Remove diaphragm by hand and discard.
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

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13. Once the anti-suffocation cover is removed, the anti-suffocation spring and anti-suffocation plate will
now be released. Remove them by hand and set to the side
14. Cup hand around the regulator and using high purity air or nitrogen, blow into the inlet quick disconnect
port to eject the anti-suffocation piston.
15. Remove O-ring ID .140 from anti-suffocation piston and discard.
Figure 5-18 Using Compressed Air Remove Piston
16. Using the 5/64 hex driver, remove the two screws from the insert body and discard.
Figure 5-19 Remove Hex Screws from Insert Body
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

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18. Once the lever is free from the crown it will drop. Remove the lever by twisting the insert body counter
clockwise while pulling on the lever. Place the lever off to the side.
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

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CAUTION
REMOVAL OF GASKETS AND O-RINGS SHOULD BE DONE WITH A
PLASTIC PICK. USE OF A METAL PICK CAN RESULT IN DAMAGE TO
COMPONENTS.
21. Using a hollow tip screwdriver, remove the crown from the insert body, turning it clockwise.
Figure 5-24 Remove Crown from Insert Body
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

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24. Remove the valve spring from the regulator body by hand and set to the side.
Figure 5-27 Remove Valve Spring
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

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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.

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