Airborne Systems SOLR 60410X Manual

TM0063
ISSUE 2 15 JANUARY 2020
OPERATOR & MAINTENANCE LEVEL 2
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 2 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
Original
Issue 1 14 June 2018 SOLR®100% Oxygen Mask Operator & Maintenance Level 2 Instructions Oliver K. Frazeur
Issue 2
15 January 2020
Added PTS to parts list, Updated parts list.
Oliver K. Frazeur

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SOLR®100% OXYGEN MASK LEVEL 2 TM0063-2
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OPERATOR & MAINTENANCE LEVEL 2
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 2 TM0063-2
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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.................................................. 3-1
Replacement of Exhaust Valve .......................................................................................................... 3-1
Removal of Exhaust Assembly .......................................................................................................... 3-4
Removal of Regulator Assembly ....................................................................................................... 3-6
Removal of Microphone Assembly ................................................................................................... 3-8
Removal of Face Straps and Hard Shell............................................................................................. 3-9
SECTION II RE-ASSEMBLE SOLR®100% OXYGEN MASK.....................................................3-11
RE-ASSEMBLY OF SOLR®100% OXYGEN MASK ....................................................................... 3-11
Adjustment Strap and Microphone Assembly ................................................................................. 3-11
Regulator Assembly ......................................................................................................................... 3-13
Exhaust Assembly............................................................................................................................ 3-15
CHAPTER 4 TROUBLESHOOTING AND PARTS LIST ................................................................. 4-1
SECTION I FUNCTIONS CHECK AND TROUBLESHOOTING THE SOLR®100% OXYGEN
MASK ....................................................................................................................................................... 4-1
TEST ...................................................................................................................................................... 4-1
Functions Check................................................................................................................................. 4-1
Functions Check Procedure................................................................................................................ 4-1
Data Sheet .......................................................................................................................................... 4-3
Table 4-1Data Sheet........................................................................................................................... 4-3
TROUBLESHOOTING......................................................................................................................... 4-5
Table 4-2 Troubleshooting................................................................................................................ 4-5
SECTION II ILLUSTRATED PARTS BREAKDOWN AND PARTS LIST ...................................4-7
ILLUSTRATED PARTS BREAKDOWN ............................................................................................ 4-7
SPARE PARTS LIST .......................................................................................................................... 4-13
Table 4-3 SOLR®100% Oxygen Mask Spare Parts .......................................................................4-13
TOOLS LIST ....................................................................................................................................... 4-17
Table 4-4 SOLR®100% Oxygen Mask Tools ................................................................................ 4-17
APPROVED FOR DISTRIBUTION ....................................................................................................... A
METRIC SYSTEM AND EQUIVALENTS ............................................................................................ C

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SOLR®100% OXYGEN MASK LEVEL 2 TM0063-2
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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; scratches, scores or otherwise damaged
surfaces that contact seals.
•Certain maintenance and repair procedures do not require complete disassembly of the oxygen mask.
NOTE
EXCESSIVE WEAR IS DEFINED AS ANY OBVIOUS DETERIORATION OR
DEFORMATION THAT MAY RENDER THE BAILOUT BOTTLE
INOPERATIVE. WHEN SERVICEABILITY OF A COMPONENT IS IN
DOUBT – REPLACE QUESTIONABLE COMPONENT.
Replacement of Exhaust Valve
NOTE
THE LOCKING WIRE MAY BE REMOVED BY OTHER MEANS, I.E.
PLIERS, IF AVAILABLE.
1. Using a knife, remove the locking wire from the exhaust cover and discard.
Figure 3-1 Remove Locking Wire from Exhaust Cover

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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).
4. Cut off excess stem from the new exhaust valve.
Figure 3-3 Cut off Excess Stem
5. Insert new exhaust valve into exhaust port ensuring it is seated properly and the stem is fully inserted
in the hole by pressing firmly on the exhaust valve.
Figure 3-4 Ensure Exhaust Valve is Seated Properly

SOLR®100% OXYGEN MASK LEVEL 2 TM0063-2
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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. Begin inserting the locking wire on the right side.
10. Continue pushing the locking wire the rest of the way in, until it is fully inserted and flush.
Figure 3-5 Install Locking Wire

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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. Using the 1/4-inch driver with medium spanner wheel, remove exhaust assembly by turning the locking
ring counter clockwise.
Figure 3-8 Remove Exhaust Locking Ring

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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

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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.
Figure 3-11 Remove Regulator Locking Ring
3. Remove the regulator assembly, locking ring and locking washer and place in a container.
Figure 3-12 Regulator Assembly, Locking Ring and Locking Washer
NOTE
ENSURE SEALING RING IS IN PLACE

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4. Using a .T8 torx driver, remove the microphone cable from the regulator.
Figure 3-13 Remove Microphone Cable from Regulator

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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.
Figure 3-15 Microphone and Microphone Housing

SOLR®100% OXYGEN MASK LEVEL 2 TM0063-2
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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. Place the hard and soft shell in clean and dry area.
Figure 3-18 Hard and Soft Shell

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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. Using a #2 phillips screwdriver and torque wrench, connect the adjustment straps to the hard shell of
the oxygen mask, to 12-inch-lbs.
Figure 3-19 Connect Adjustment Straps to Mask
2. Place the microphone gasket on the microphone with the prongs going through the center holes of the
gasket.
Figure 3-20 Place Microphone Gasket on Microphone

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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.
Figure 3-22 Align Microphone through the Center Holes
4. Using a #0 phillips screwdriver, secure the microphone housing to the microphone until snug.
Figure 3-23 Secure the Microphone Housing to the Microphone