MSA MMR Quick start guide

MMR™ Air Mask
MSA 2002 Edition
TAL 801 (L) Rev. 5 MSA 2008 Prnt. Spec. 10000005389(A) Mat. 10039500
Doc. 10000014102
The NightFighter™ Heads-Up Display System complies with Part 15 of the FCC
Rules.
Operation is sub ect to the following conditions:
(1) This device may not cause harmful interference and
(2) This device must accept any interference that may cause
undesired operation.
This manual must be carefully read and followed by all persons who have or will have
the responsibility for using or servicing this air mask. This air mask will perform as
designed only if used and serviced according to the instructions; otherwise it could fail
to perform as designed, and persons who rely on the air mask could sustain serious
personal in ury or death.
UPGRADE INSTRUCTIONS
Changes and modifications not expressly approved by the manufacturer could
void the User’s authority to operate the equipment.
The warranties made by MSA with respect to the product are voided if the prod-
uct is not installed, used and serviced in accordance with the instructions in this
manual. Please protect yourself and your employees by following the instructions.
Please read and observe the WARNINGS and CAUTIONS inside. For any additional
information relative to use or repair, write or call 1-800-MSA-2222 during regular
working hours.
DO NOT use a 2216psi air cylinder on a 3000psi operating system. Such a configura-
tion is not approved by NIOSH. Failure to follow this warning can result in serious per-
sonal in ury or death.
NOTICE
Installation of this upgrade kit will provide the functionality intended by the NFPA
19 1-2002 Edition Standard, however the air mask cannot be considered NFPA 2002
Edition Compliant, since the NFPA 19 1-2007 Edition Standard is currently in effect.
For new air mask or upgrades, the NFPA only recognizes compliance to the current
edition of the standard.

INTRODUCTION
IMPORTANT NOTICE
A thorough understanding of the air mask is essential
before attempting to service or maintain this air mask. A
User's Instruction Manual is supplied with each new air
mask. Refer to the User's Instructions for specific user
information, such as NIOSH Approval Information, don-
ning and doffing, or cleaning and disinfecting.
This air mask will perform as designed only if used and
maintained according to the manufacturer's instructions.
You must read and understand these instructions before
trying to use or service this product. We encourage our
customers to write or call for information on this product
before using it.
If the air mask does not perform as specified in this man-
ual, it must not be used until it has been checked by
authorized personnel.
Do not alter, modify, or substitute any components with-
out the approval of the manufacturer. Such alterations will
void the NIOSH approval.
Inspect the air mask regularly and maintain it according to
the manufacturer's instructions. Repairs must only be
made by properly trained personnel. Only certified per-
sonnel must do any additional repairs NOT covered by
this manual.
DO NOT attempt repairs beyond those specified in this
manual. Only trained or certified personnel, authorized
by MSA, are permitted to maintain and repair this
apparatus. Breathing apparatus must not be repaired
beyond the manufacturer's recommendations. 29 CFR
Part 1910.134, Par. (f) (4) makes these requirements
clear:
Replacement or repairs shall be done only by experi-
enced persons with parts designed for the respirator.
No attempt shall be made to replace components or
to make adjustment or repairs beyond the manufac-
turer's recommendations. Regulators shall be returned
to the manufacturer or to a trained technician for
adjustment or repair. Failure to follow this warning can
result in serious personal injury or death.
DO NOT install a Quick-Fill System and 3000psi URC
Assembly on the same air mask. Combining there
assemblies on the same air mask will not allow the
relief valve in the 3000psi URC Assembly to open as
designed. Failure to follow this warning can result in
serious personal injury or death.
DO NOT Transfill (be a Donor) using a 3000psi URC
Assembly. The 3000psi URC Assembly has a check
valve that does not allow cylinders to Transfill (be a
Donor). Failure to follow this warning can result in
serious personal injury or death.
Using the 3000psi URC Assembly to fill cylinders, the
cylinder can only be filled to 2216psig. If the pressure
exceeds 2216psig a Relief Valve in the URC Assembly
will vent at approximately 2525psig or as low as
2400psig. A 3000psig cylinder can only be filled to
3000psig by using a secondary air source; the 3000psi
URC Assembly can not be used for filling a 3000psig
cylinder. Failure to follow this warning can result in
serious personal injury or death.
DO NOT inspect the apparatus before cleaning if there
is a danger of contacting hazardous contaminants.
Clean and sanitize first, then inspect. Failure to follow
this warning can cause inhalation or skin absorption
of the contaminant and result in serious personal
injury or death.
2
TAL 801 (L) Rev. 5 - 10039500
TABLE OF CONTENTS
ImportantNotice ..................................................................................2
Inspection........................................................................................3
GeneralInspectionCheckPoints .....................................................................3
NightFighter™ Heads-Up Display System Bracket and Transmitter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
UltraEliteFacepieceDisassembly ....................................................................5
InstallationofReceiverBracketandCover ..............................................................7
InstallationforTransmitter ...........................................................................7
Removing the ICM®Unit ............................................................................9
InstallingtheTransmitterontheGaugeLine............................................................11
LeakTesting .....................................................................................15
Upgrading Instructions for URC Assembly (Universal Rescue Connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

INTRODUCTION
An AIR MASK cannot be upgraded until the following
inspection and all required changes have been com-
pleted:
Inspection
Inspect the entire air mask after it is cleaned and sani-
tized. NFPA-1500, as well as ANSI Standards Z88.2 and
Z88.5, describe three levels of inspection procedures that
are to be performed. Refer to these documents or to an
inspection program prepared by a health professional in
establishing an inspection program.
Note: If the air mask being upgraded does not have a
secondary end of service time indicator, the NightFighter
Heads-Up Display System will serve as a secondary
alarm.
NIOSH APPROVAL LABELS AND USER’S
INSTRUCTIONS
This Upgrade Kit includes NIOSH Approval Labels and
User’s Instructions for both the MMR 1⁄4 Turn and
Firehawk Regulators.
To determine which label and User’s Instructions to select,
reference the following table and keep the correct
approval label and User’s Instructions for the AIR MASK
to be upgraded.
Discard the label and User’s Instructions that DO NOT
apply.
Prior to installation of this Upgrade Kit, the Air Mask must
be upgraded to be compliant with the 1997 Edition of the
NFPA-1981 Standard. The components must be in good
working order, free of damage and significant wear.
If any component of the air mask being upgraded is
missing or needs to be replaced due to wear or dam-
age, replace the affected component before you install
the upgrade kit. Used, worn, or damaged parts can
result in serious personal injury or death.
In addition to the inspection of required, the following
general inspection of the apparatus must be performed
before installing this upgrade.
GENERAL INSPECTION CHECK POINTS
1. Don the air mask following the original instructions
provided by MSA. These steps make up the air mask
functional test.
2. If all steps are performed successfully, remove the air
mask and inspect it following the steps below:
3. Facepiece
a. Inspect the facepiece for rubber deterioration, dirt,
cracks, tears, holes, or tackiness.
b. Check the harness headstraps for breaks, loss of
elasticity, or missing buckles or straps. Check the
strap serrations for signs of wear.
c. The exhalation valve must be clean and operate
easily. Reach into the facepiece. Push and release
the valve stem several times. The valve must move
off the seat and return when released.
d. Inspect the facepiece coupling for damage. Also
check to be sure the spider gasket, o-ring, and
valve disc are present.
4. Cylinder Redundant Alarm, Pressure Gauge or ICM
Unit
a. Be sure you can see both gauge needles and faces
clearly through the lens. Also be sure the gauge
stem is not bent.
5. Audible Alarm
a. Check that the bell is in the proper alignment and
fastened securely.
b. If the bell is loose, remove the alarm from service.
c. Unscrew the Audi-Larm coupling nut from the cylin-
der valve. It is hand-tightened and should not
require tools. Inspect the coupling nut for thread
damage. Also be sure there is an o-ring and that it
is not damaged. Replace the insert o-ring if it is
damaged.
6. High Pressure Hose
a. Check the high pressure hose between the alarm
and the regulator. Look for cuts or severe abrasions.
If present, replace the hose. The hose fitting should
be tight.
7. Quick-Connect Second Stage Intermediate Hose
a. Inspect rubber washer for deterioration, dirt, cracks,
tears, or tackiness.
8. Cylinder
a. Inspect the cylinder valve for signs of damage. The
valve may be opened slightly to be sure it operates
properly. Be sure to fully close the valve.
b. Inspect the cylinder body for cracks, dents, weak-
ened areas, or signs of heat-related damage. If the
cylinder is damaged, return it to an MSA Service
Center. Call 1-800-MSA-2222 for instructions.
3TAL 801 (L) Rev. 5 - 10039500
Regulator
MMR 1⁄4 Turn
MMR Firehawk
(Slide and Push- o-Connec )
NIOSH Approval
Label
P/N 816731
P/N 10024128
User’s Instructions
P/N 10041847
P/N 10023638

INTRODUCTION
Note: Check the hydrostatic test date on the cylinder
approval sticker located on the cylinder neck. Composite
cylinders must be tested every three years. Steel cylinders
must be tested every five years.
9. Carrier and Harness
a. Inspect all harness and carrier components for cuts,
tears, abrasions, or signs of heat or chemical-relat-
ed damage. Check that tee nuts, washers, and
screws are secured.
b. Inspect the cylinder band and latch to be sure it
holds the cylinder securely. Operate the latch wing
to be sure that it opens and closes properly and
that it holds the cylinder securely. If the cylinder
band and latch is locked, the latch wing should not
turn.
After all inspections have been completed successfully,
install the upgrade kit.
Note: The upgrade kit can only be used with Ultra Elite
Facepiece with nosecup.
The high pressure hose must be replaced with a longer
hose for Black Rhino or Wolverine Carrier and Harness
Assembly (new hose assembly, P/N 10037954).
Only MSA-Certified Technicians are authorized to
install the Upgrade Kit.
4
TAL 801 (L) Rev. 5 - 10039500

NIGHTFIGHTER HEADS-UP DISPLAY SYSTEM INSTALLATION
Note: The Nightfighter Heads-Up Display System has
been tested and found to comply with the limits for a
Class B digital device, pursuant to Part 15 of the FCC
Rules. These limits are designed to provide reasonable
protection against harmful interference in a residential
installation. This equipment generates, uses and can radi-
ate radio frequency and, if not installed in accordance
with instructions, may cause harmful interference to radio
communications. However, there is no guarantee that
interference will not occur in a particular installation. If this
equipment does cause interference to radio or television
reception, which can be determined by turning the equip-
ment off and on, the user is encouraged to try to correct
the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and
the receiver.
• Connect the equipment into an outlet on a circuit dif-
ferent from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV techni-
cian for help.
BRACKET AND TRANSMITTER KIT
If the air mask being upgraded has a DragonFly IP Pass
installed, MSA Left Shoulder Gauge Line Kit, P/N
10042264 or P/N 10043335, is also required.
DESCRIPTION
The NightFighter Heads-Up Display System Bracket and
Transmitter Kit is designed to attach to an MSA Ultra Elite
Facepiece to allow the easy attachment and removal of
the NightFighter Heads-Up Display System.
Note: The NightFighter Heads-Up Display System can
only be used with an Ultra Elite Facepiece.
ICM TX UNIT
The ICM Tx Unit is assembled to the gauge line and
serves as the transmitter for the NightFighter Heads-Up
Display System.
ULTRA ELITE FACEPIECE DISASSEMBLY
Removing the Component Housing Cover for MMR 1/4
Turn
1. Remove the two component housing cover screws
and spacers. Remove the neckstrap.
2. Remove the locking ring.
3. Lift up on the cover release hook, located forward of
the adapter assembly opening. Once the release is lift-
ed, remove the cover by pulling it away from the hous-
ing. Tilt the cover and work it over one adapter bayo-
net at a time.
Removing the Component Housing Cover for MMR
Firehawk with Push-To-Connect Adapter
1. Remove the two component housing cover screws.
Remove the neckstrap.
Note: The cover wall must be between the connection
collar and the adapter flange to allow the adapter to
rotate.
2. Lift up on the cover release hook, located forward of
the adapter assembly opening. Lift up on the cover,
hold the cover up, and unthread the adapter.
Removing the Component Housing Cover for MMR
Firehawk with Slide Connection
1. Remove the two component housing cover screws.
Remove the neckstrap.
2. Lift up on the cover. Remove the cover by pulling it
away from the housing. Tilt the cover and work it over
adapter.
3. Unthread and remove the adapter assembly.
Be careful that you do not damage internal parts of
the component housing assembly (exhalation valve,
spring, retainer, or speaking diaphragm) once the
cover is removed.
Note: The following procedures are for MMR 1/4 Turn,
MMR Firehawk with Slide Connection, or MMR Firehawk
with Push-To-Connect Facepieces:
5TAL 801 (L) Rev. 5 - 10039500

NOTES
6
TAL 801 (L) Rev. 5 - 10039500

INSTALLATION
INSTALLATION OF RECEIVER BRACKET AND COVER
Installing the Mounting Bracket to the Facepiece
1. Using a phillips screwdriver, loosen and remove the
screw from right side of the facepiece lens retaining
ring. (Be sure not to lose the nut, if applicable).
2. Slide the bracket assembly onto the facepiece. Make
sure that molded tab of bracket is under the lower
lens ring.
3. Position the upper metal tab of the mounting bracket
over the screw hole in the upper lens ring. Re-install
the screw. Make sure that the screw goes through the
hole in the upper metal tab. Tighten firmly.
4. Ensure the alignment of screw hole in the lower metal
tab over component housing screw hole.
DO NOT damage internal parts of the component
housing assembly (exhalation valve, spring, retainer, or
speaking diaphragm) once the cover is removed.
Installing the Component Housing Cover for MMR 1/4
Turn
1. Place the component housing cover over the adapter
assembly. Tilt and rotate the cover to work it over one
bayonet at a time.
2. Insert the tab on the cover into the slot in the lens
ring.
3. Press in on the front of the cover until the cover hook
snaps into place.
4. Install the locking ring by sliding it into the groove on
the adapter. (Do not slide it into the space between
the slip nut flange and the adapter flange.)
5. Place the spacers and the neckstrap brackets in the
cover sockets under the locking ring. Install the
phillips head screws through the bracket, spacer,
cover, and metal top of bracket. Tighten firmly.
6. Verify each of the following features:
a. The adapter bayonets are locked into a horizontal
position and CANNOT be rotated.
b. The slip nut is threaded completely into the face-
piece and locked securely. It CANNOT be rotated.
c. The metal locking ring is locked into position and
CANNOT be rotated.
d. There is no loose play in the assembly of parts.
7. Don the facepiece and check the face-to-facepiece
seal. Follow the Facepiece Fit Check Procedures in
the MMR Operations and Instructions Manual.
Installing the Component Cover for MMR Firehawk
with Push-To-Connect Adapter
1. Insert the adapter through the component housing
cover.
2. Insert the tab on the cover into the slot in the lens
ring. Thread the adapter into the component housing
keeping the cover wall between the connection collar
and the adapter flange. Tighten the adapter firmly.
3. Push in on the top cover until the cover hook locks
into place. Line up the screw holes in the cover with
the screw hole in the lower metal tab of the mounting
bracket and the threaded inserts in the component
housing.
4. Place the neckstrap’s bracket into the cover sockets.
Install the phillips head screws through the neck-
strap’s bracket, the cover, and the lower metal tab of
the mounting bracket then tighten firmly.
5. Ensure all items are secure and tighten firmly.
Installing the Component Housing Cover for MMR
Firehawk with Slide Connection
1. Place the component housing cover over the adapter
assembly.
2. Insert the tab on the cover into the slot in the lens
ring. Press in on the front of the cover until the cover
hook snaps into place.
3. Line up the screw holes in the cover with the metal
tab of mounting bracket and threaded inserts in the
housing.
4. Place the neckstrap brackets into the cover sockets.
Install the new phillips head screws. Tighten firmly.
5. Verify that there is no loose play in the assembly of
parts.
6. Don the facepiece and check the face-to-facepiece
seal. Follow the Facepiece Fit Check Procedures in
the MMR with Slide Connection Operation and
Instructions Manual (P/N 10023638).
INSTALLATION FOR TRANSMITTER OR ICM TX UNIT
This kit supplies the parts necessary to add the
NightFighter Heads-Up Display System Transmitter or
ICM Tx Unit to the following air mask:
• MMR without Quick-Fill System option
• MMR with Quick-Fill System option installed
• MMR with Redundant Alarm installed (NightFighter
transmitter only)
• MMR with ICM Unit 2000/ICM Unit 2000 Plus installed
(NightFighter transmitter only)
7TAL 801 (L) Rev. 5 - 10039500
UPPER METAL TAB
MOLDED TAB
LOWER METAL TAB

INSTALLATION
DO NOT install a Quick-Fill System and 3000psi URC
Assembly on the same air mask. Combining these
assemblies on the same air mask will not allow the
relief valve in the 3000psi URC Assembly to open as
designed. Failure to follow this warning can result in
serious personal injury or death.
Only MSA-certified technicians are authorized to
install the Upgrade Kit.
COMMON PARTS
• 638166 O-ring
• 635277 Back-up ring (3)
• 10003605 Spool
REQUIRED TOOLS
The tools contained in the tool kit supplied to certified
repairpersons would be sufficient to install this kit.
Before starting the procedures below, ensure that the
cylinder valve is completely closed. Ensure nothing
blocks the regulator outlet. Open the bypass valve to
relieve any pressure in the system. Failure to follow
this warning can cause serious personal injury or
death.
Note: If AIR MASK does not have the Quick-Fill System
option installed on the over-the-shoulder gauge line hose,
remove the gauge from the MMR harness gauge hose.
1. Close the bypass valve fully.
DO NOT disconnect the alarm coupling nut when
pressure is shown on the harness gauge. Always be
sure that you have released all pressure from the reg-
ulator. Removing the coupling nut with the regulator
pressurized can result in serious personal injury or
death.
2. Unscrew the alarm coupling nut from the cylinder
valve.
8
TAL 801 (L) Rev. 5 - 10039500

DISASSEMBLY
REMOVING PRESSURE GAUGE OR REDUNDANT
ALARM
DO NOT disconnect the alarm coupling nut when pres-
sure is shown on the harness gauge. Always be sure
that you have released all pressure from the regulator.
Removing the coupling nut with the regulator pressur-
ized can result in serious personal injury or death.
Note: All repair procedures assume that the alarm assem-
bly is disconnected from the apparatus cylinder.
1. Be sure the cylinder is completely closed.
2. Be sure nothing blocks the regulator outlet. Open the
bypass valve to relieve pressure in the system.
3. Using 5/8" wrenches, loosen and remove the pressure
gauge and redundant alarm from the pressure gauge
hose. Set the gauge and alarm aside.
Note: The redundant alarm cannot be re-used. If the pres-
sure gauge is removed, the pressure gauge can be re-
used only if upgrading to 2216psi or 4500psi. When
upgrading to 3000psi a new pressure gauge, P/N
10047235, must be used.
4. Using the o-ring removal tool, remove the O-ring and
back-up ring from the end of the hose.
REMOVING QUICK-FILL SYSTEM OPTION
DO NOT install a Quick-Fill System and 3000psi URC
assembly on the same air mask. Combining these
assemblies on the same air mask will not allow the
relief valve in the 3000psi URC Assembly to open as
designed. Failure to follow this warning can result in
serious personal injury or death.
1. Using wrenches. Unthread and remove the existing
Quick-Fill System block and pressure gauge from the
gauge hose fitting.
2. Using the o-ring removal tool. Remove the o-ring and
back-up ring from the end of the gauge hose fitting.
Note: Salvage the quick-fill system (male) coupling from
the existing block. Discard the quick-fill block and filter.
Salvaging Quick-Fill (male) Coupling
1. Place the quick-fill block in a vise. Use protective
sleeves on the vise to keep from damaging the block.
2. Unthread the quick-fill (male) coupling from the quick-
fill block using a 1" deep-well socket.
3. Discard the adapter block.
4. Using the o-ring removal tool, remove and discard the
existing o-ring (P/N 635068) from the quick-filll system
(male) coupling (P/N 485070). (See Installing the
Transmitter on the Gauge Line)
Note: If transmitter block does not have the quick-filll sys-
tem (male) coupling, Then follow procedures for Installing
the quick-fill system (male) coupling in the transmitter.
REMOVING THE ICM UNIT
DO NOT disconnect the alarm coupling nut when
pressure is shown on the harness gauge. Always be
sure that you have released all pressure from the reg-
ulator. Removing the coupling nut with the regulator
pressurized can result in serious personal injury or
death.
Note: All repair procedures assume that the alarm assem-
bly is disconnected from the apparatus cylinder.
1. Be sure the cylinder valve is completely closed.
2. Be sure that nothing blocks the regulator outlet. Open
the bypass valve to relieve pressure in the system.
Removing the ICM Unit
1. Hold hose nut with 5/8" wrench and slide the other
wrench over jam nut and loosen jam nut counter-
clockwise.
2. Unthread ICM unit.
3. Remove OLD jam nut. Discard the OLD jam nut.
4. Ensure that the spool is present in the ICM Unit outlet.
9TAL 801 (L) Rev. 5 - 10039500

DISASSEMBLY
DO NOT re-use the OLD jam nut. Dispose of it imme-
diately. Failure to follow this warning could result in
personal injury.
Note: For 3000psi Air Mask’s, Discard old ICM Units and
install new 3000psi ICM Unit.
REMOVING THE ICM UNIT FROM THE QUICK-FILL
SYSTEM BLOCK
Over-the-shoulder quick-fill system configuration is
not compatible with the 3000psi Operating System Air
Mask. Failure to follow this warning can result in seri-
ous personal injury or death.
1. Use a wrench to hold the quick-fill system block or
place quick-fill system block in a vise using protective
sleeves to keep from damaging the block.
2. Hold the quick-fill system block with the 5/8" wrench
and slide the other wrench over jam nut and loosen
jam nut counter clockwise.
3. Unthread the ICM Unit from quick-fill system block.
4. Remove the OLD jam nut from the ICM Unit. Discard
the OLD jam nut.
5. Ensure that the spool is present in the ICM Unit outlet.
DO NOT re-use the OLD jam nut. Dispose of it imme-
diately. Failure to follow this warning can result in seri-
ous personal injury or death.
Note: For 3000psi air masks, discard the old ICM Units
and install the new 3000psi ICM Unit.
10
TAL 801 (L) Rev. 5 - 10039500

INSTALLATION
INSTALLING THE TRANSMITTER ON THE GAUGE
LINE
1. Apply a thin film of Christo-Lube Lubricant to a new
back-up ring. Place the back-up ring in the groove on
the end of the hose fitting.
2. Apply a thin film of Christo-Lube Lubricant to a new o-
ring. Place the o-ring in the groove on the end of the
hose fitting.
3. Insert the hose fitting into the transmitter block.
Torque the adapter to 50-60 in.lbs.
Note: If the apparatus was equipped with the redundant
alarm or ICM Unit its pressure gauge will have the spool
included. Make sure that the spool stays with the gauge.
Note: If the spool is not installed. (See Installation of
Spool)
Installation of Plug
Note: The plug is only used if the apparatus was not
equipped or will not being equipped with the pressure
gauge or ICM Unit inserted into the transmitter block.
1. Apply a thin film of Christo-Lube Lubricant to back-up
ring (P/N 635277). Place back-up ring in the groove on
end of the plug.
2. Apply a thin film of Christo-Lube Lubricant to o-rings
(P/N 638167). Place o-ring in the groove on end of the
plug.
3. Thread the plug into the transmitter block. Torque the
plug to 175+/-25 in.lbs.
Note: See Installation Instructions for pressure gauge or
ICM Unit.
INSTALLING THE PRESSURE GAUGE OR ICM UNIT
CLEANING
1. Apply alcohol to a Q-Tip applicator.
a. Wipe the threads on the pressure gauge or the ICM
Unit and the wipe jam nut (dull surface finish).
b. Wipe the threads of the pressure gauge or the ICM
Unit port of quick-fill system block.
2. Let the alcohol dry for 15 seconds.
INSPECTION
1. Inspect the threads of the pressure gauge or the ICM
Unit and the jam nut for any damage.
Note: If the apparatus is equipped with the pressure
gauge or ICM Unit, it will have the spool included. Ensure
the spool is in the the ICM Unit (See Installation of Spool).
Installation of Spool
1. Apply a thin film of Christo-Lube Lubricant to two
back-up rings (P/N 635277). Place one back-up ring in
the groove on each end of the spool.
2. Apply a thin film of Christo-Lube Lubricant to two o-
rings (P/N 638167). Place one o-ring in the groove on
each end of the spool.
3. Insert the spool into the
pressure gauge or ICM
Unit. The spool's larg-
er-diameter hole must
face toward the gauge.
Note: Redundant alarm cannot be re-used. If the pressure
gauge is removed, the pressure gauge can be re-used
only if upgrading to 2216psi or 4500psi. When upgrading
to 3000psi a new pressure gauge P/N 10047235 must be
used.
11 TAL 801 (L) Rev. 5 - 10039500

INSTALLATION
INSTALLATION OF PRESSURE GAUGE OR ICM UNIT
Note: Prior to applying Loctite ensure the threads on the
pressure gauge or ICM Unit are wiped clean.
1. Apply Loctite 271 on two threads approximately a
tenth (0.10) of an inch from the thread shoulder of the
pressure gauge or the ICM Unit as shown.
Note: Do not re-use old jam
nut.
2. Thread the jam nut
(supplied with kit)
against the threaded
shoulder of pressure
gauge or ICM Unit as
per view shown.
3. Apply Loctite 271
to three threads,
approximately one
sixteenth (0.060)
of an inch from the
end of the pres-
sure gauge or the
ICM Unit as
shown.
4. Thread the pressure gauge or ICM Unit into the
transmitter until it stops.
DO NOT try to screw the small-diameter (tapered
thread) gauge (P/N 495764 or 495765) into the trans-
mitter. Use the larger-diameter gauge (P/N 10003610,
P/N 10003611 or 3000psi gauge P/N 10047235) with a
straight thread. Failure to follow this warning can
result in serious personal injury or death.
5. Thread the pressure gauge or ICM Unit into the trans-
mitter block. The gauge must screw into the transmit-
ter block at least 6 1/2 turns with the jam nut firmly
against the transmitter block.
DO NOT tighten the gauge by hand. Use wrenches.
Use only gauges (P/N 10003610, P/N 10003611 or
3000psi gauge P/N 10047235) with a straight thread.
Failure to follow this warning can result in serious per-
sonal injury or death.
a. If the gauge is not facing out (away from the shoul-
der pad), unthread the gauge not more than one
turn to obtain this alignment. Hold the pressure
gauge or ICM Unit to prevent turning.
b. Hand-tighten the jam
nut against the
transmitter and
torque to 225-
250in.lbs. See view
for suggested torque
wrench orientation.
DO NOT tighten pressure gauge or ICM Unit by hand.
Use wrenches.
DO NOT unthread the gauge more than one full turn.
The gauge-adapter connection may leak, resulting in
serious personal injury or death.
7. Ensure the pressure gauge or ICM Unit guard is in
place around the gauge.
8. Check that the dust cover is installed on the gauge
hose above the transmitter block. If transmitter has
Quick-Fill coupling installed. (See installing the Quick-
Fill Coupling Section)
DO NOT unthread the pressure gauge or ICM Unit,
more than one full turn. The gauge-adapter connec-
tion may leak, resulting in serious personal injury or
death.
9. Make sure the pressure gauge or ICM Unit guard is in
place around the gauge.
12
TAL 801 (L) Rev. 5 - 10039500
0.10 of inch
Loctite
Thread Shoulder
New Jam Nut
0.060 of inch
Loctite

INSTALLATION
INSTALLING THE QUICK-FILL COUPLING IN THE
TRANSMITTER ADAPTER PORT
Over the shoulder Quick-Fill System configuration is
not compatible with the 3000psi Operating System Air
Mask. Failure to follow this warning can result in seri-
ous personal injury or death.
Note: The quick-fill system coupling can only be salvaged
by installing into Audi-Larm for 3000psi Operating System
air mask. Refer to Removing the Quick-Fill System
Adapter Block section.
1. Place the transmitter block in a vise. Use protective
sleeves to keep from damaging the block.
2. Wrap the coupling threads with transparent tape to
prevent damage to the o-ring.
a. Apply a thin film of Christo-Lube Lubricant to the
P/N 635068 coupling o-ring.
b. Slide the new o-ring
over the coupling
threads. Remove the
tape.
3. Thread the coupling into the block and tighten to 70-
75 ft.lbs. using a 1" deep-well socket.
13 TAL 801 (L) Rev. 5 - 10039500

NOTES
14
TAL 801 (L) Rev. 5 - 10039500

LEAK TESTING
Over-the-shoulder quick-fill system configuration is
not compatible with the 3000psi Operating System Air
Mask. Failure to follow this warning can result in seri-
ous personal injury or death.
CHECKING FOR LEAKS AND PROPER OPERATION
1. Follow the User's Instructions supplied with the air
mask to connect the Audi-Larm™ Audible Alarm to a
fully charged cylinder.
2. Check that the bypass is closed.
DO NOT try to connect a high pressure (4500psig)
cylinder to a low pressure apparatus. Even though the
coupling nut will not thread all the way on the cylinder
valve and bleed holes in the cylinder valve will let the
air escape and not enter the system, this is a danger-
ous condition. Failure to follow this warning can result
in serious personal injury or death.
DO NOT use a 2216psi Air Cylinder on a 3000psi
Operating System. Such a configuration is not
approved by NIOSH. Failure to follow this warning
can result in serious personal injury or death.
3. Open the cylinder valve fully. The (pressure gauge or
ICM Unit) remote gauge should indicate the pressure
in the cylinder.
4. Close the cylinder valve and watch the (pressure
gauge or ICM Unit) remote gauge. There should be no
drop in pressure if the apparatus is leak-tight. If the
gauge needle moves, check the components for leaks
using leak detection solution. Follow the Leak Test
Procedures in the Air Mask Maintenance Manual.
Correct any leaks before proceeding.
5. Be sure the cylinder valve is fully closed. Open the
bypass valve to relieve all pressure from the system.
6. After all pressure is relieved from the system, close the
bypass valve completely.
7. The air mask is now ready for service.
8. Read and be sure that you fully understand the
instructions for operating the NightFighter Heads-Up
Display System before use. These instructions are
located in the NightFighter Heads-Up Display System
Instruction Manual P/N 10035580.
15 TAL 801 (L) Rev. 5 - 10039500

NOTES
16
TAL 801 (L) Rev. 5 - 10039500

UPGRADING INSTRUCTIONS
UPGRADING INSTRUCTIONS FOR URC (UNIVERSAL
RESCUE CONNECTION) ASSEMBLY
MAINTENANCE
The maintenance procedures authorized in this manual
need no special training, although the user must have a
thorough understanding of the apparatus. All maintenance
procedures are for prior or current designs, unless speci-
fied. Additional, advanced training is available. Contact
your MSA representative for details.
Leak testing should be performed when the Air Mask fails
any of the inspection steps following disassembly or as
part of a regularly scheduled maintenance procedure. The
Air Mask must hold system pressure without leaks to pro-
vide adequate protection. The component leak test proce-
dure is the first step in trouble-shooting. These tests ensure
that you do not have a leak. Leak testing quickly identifies
components which need repair or replacement. Use P/N
600920 leak test solution or prepare a soapy water solu-
tion. Be sure to use enough soap to produce bubbles.
DO NOT tighten fittings or connectors when the system
is pressurized. Close the cylinder valve. Be sure nothing
blocks the regulator outlet. Relieve pressure from the
system by slowly opening the bypass valve. Failure to
follow this warning can cause fittings or connectors to
rupture, resulting in serious personal injury or death.
GENERAL NOTES
The inspection and maintenance procedures authorized in
this manual are classified User Maintenance. Additional,
advanced training is available. Contact your MSA repre-
sentative for details. Refer to the appropriate Illustrated
Parts List.
IMPORTANT
You must read and understand the General Notes,
Warnings, and Cautions below before performing
Disassembly and Repair. General Notes is a collection of
procedures common to many repairs. Details for each
procedure are listed below. Details are not repeated each
time the procedure is done. Instead, a reference to the
General Note appears in the text.
DO NOT attempt repairs beyond those specified in this
manual. Breathing apparatus must not be repaired
beyond the manufacturer's recommendations. Failure
to follow this warning can result in serious personal
injury or death.
Note 1: Lubricate all designated O-rings with a very thin
film of Christo-Lube Lubricant (P/N 604070) before they
are installed. Christo-Lube Lubricant is compatible with
brass and aluminum.
DO NOT over-tighten parts or the part or the fitting
threads may be damaged.
Note 2: All repair procedures assume that the Audi-Larm
Assembly is disconnected from the apparatus cylinder.
Be sure the cylinder valve is completely closed.
Be sure that nothing blocks the regulator outlet. Open the
bypass valve to relieve pressure in the system.
Close the bypass valve fully.
DO NOT disconnect the Audi-Larm coupling nut when
pressure is shown on the harness gauge. Always be
sure that you have released all pressure from the regu-
lator. Removing the coupling nut with the regulator
pressurized can result in serious personal injury or
death.
Unscrew the Audi-Larm coupling nut from the cylinder
valve.
Note: The following procedures are for the Black Rhino
and Wolverine Carrier and Harness Assemblies, the high
pressure hose from the first stage regulator to the URC
Assembly must be replaced with a new hose assembly
P/N 10037954.
All repair procedures assume that the Audi-Larm Audible
Alarm is disassembled from the cylinder. (See Note 2)
Black Rhino and Wolverine Carrier and Harness
Procedures
1. Removing the high pressure hose from the first stage
regulator
a. Using a 1/4" socket, remove the two screw pins
from the regulator body.
b. Pull firmly on the high pressure hose to remove it
from the regulator body.
c. Remove the old O-ring and back-up ring. Be careful
not to damage the O-ring seal area.
2. Removing the high pressure hose from Audi-Larm
Assembly
a. Clamp the Audi-Larm body in a vise.
Be careful that you do not damage the bell or the hos-
ing with the vise. Use shields on the vise jaws.
17 TAL 801 (L) Rev. 5 - 10039500

UPGRADING INSTRUCTIONS
b. Place a wrench on the hex flats of the hose fitting.
Unthread in a counter-clockwise direction to remove
the high pressure hose.
c. Using the o-ring removal tool, remove the o-ring from
the hose fitting. Be careful. Do not damage the o-ring
seal.
d. Discard Audi-Larm Assembly.
3. Installing the new high pressure hose into the new URC
Assembly:
a. Use transparent tape to cover the hose fitting
threads. Install a new o-ring on the high pressure
hose fitting. Lubricate the o-ring (see General
Note 1).
b. Clamp the URC Assembly body in a vise.
Be careful that you do not damage the bell or the hos-
ing with the vise. Use shields on the vise jaws.
c.Remove tape.
d. Hand-tighten fitting clockwise into the URC
Assembly outlet.
e. Tighten with a crowsfoot wrench to a torque of 100-
140 in.lbs.
4. Installing the high pressure hose into the first stage
regulator
a. Install a new back-up ring and a new o-ring on the
hose fitting. (Refer to General Note 1)
b. Insert the high pressure hose into the regulator body.
c. Insert a new screw pin into each of the two holes in
the regulator body.
d. Use a socket to tighten the pins to a torque of 10-15
in.lbs.
Note: The following procedures are for the Vulcan Carrier
and Harness Assembly.
Vulcan Procedures
1. Removing the high pressure hose from the Audi-Larm
a. Clamp the Audi-Larm body in a vise. Remove tape
from hose threads.
Ensure the bell or the hosing are not damaged with the
vise. Use shields on the vise jaws.
b. Place a wrench on the hex flats of the hose fitting.
Unthread in a counter clockwise direction to remove
the high pressure hose.
c. Using the o-ring removal tool, remove the o-ring from
the hose fitting. Be careful. Do not damage the o-ring
seal.
d. Discard Audi-Larm.
2. Installing the high pressure hose into URC Assembly
a. Use transparent tape to cover the hose fitting
threads. Install a new o-ring on the high pressure
hose fitting. Lubricate the o-ring (Refer to General
Note 1).
b. Clamp the URC Assembly body in a vise. Remove
tape from hose threads.
Ensure the bell or the hosing are not damaged with the
vise. Use shields on the vise jaws.
3. Thread hose fitting clockwise into the URC Assembly
outlet.
4. Tighten with a crowsfoot wrench to a torque of 100-140
in.lbs.
Note: The following procedures for replacing Quick-Fill
System adapter block and using the Quick-Fill System cou-
pling (male adapter) from old Quick-Fill System to install
into URC Assembly is optional, except when upgrading to
3000psi Air Mask. The Quick-Fill System coupling must be
removed from the over-the-shoulder block and installed
into URC Assembly.
Over-the-shoulder quick-fill system configuration is not
compatible with the 3000psi Operating System Air
Mask. Failure to follow this warning can result in
serious personal injury or death.
Removing the Quick-Fill System Adapter Block
1. Using wrenches, unthread and remove the existing
quick-fill system block and any pressure gauge assem-
bly from the gauge hose fitting.
2. Using the o-ring removal tool, remove the o-ring and
back-up ring from the end of the gauge hose fitting.
Note: Salvage the quick-fill system coupling from the exist-
ing block. Discard quick-fill system block and filter.
3. Place the adapter block in a vise. Use protective
sleeves to keep from damaging the block and coupling.
Unthread the coupling from the block using a 1" deep-
well socket. Set the adapter block aside.
4. Remove and discard the existing O-ring (P/N 635068)
from the Quick-Fill System coupling (P/N 485070). Use
the O-ring removal tool to remove the O-ring.
5. Install transmitter block (Refer to Installing the
Transmitter Block section).
Installing the Coupling (male adapter) in the URC
Assembly
1. Place the URC Assembly in a vise. Use protective
sleeves to keep from damaging the URC Assembly.
2. Wrap the coupling threads with transparent tape to pre-
vent damage to the o-ring. Apply a thin film of Christo-
Lube lubricant to the coupling o-ring (P/N 635068).
3. Slide the new o-ring over the coupling threads. Remove
tape.
4. Thread the coupling into the URC Assembly coupling
port. Tighten to a torque of 70-75 ft.lbs. using a torque
wrench and a 1" deep-well socket.
18
TAL 801 (L) Rev. 5 - 10039500

UPGRADING INSTRUCTIONS
Note: Ensure the hex flats of the coupling are not rounded
off when applying the 70-75 ft.lbs. of torque.
5. Remove the URC Assembly from the vise.
INSTALLATION OF NIOSH APPROVAL LABEL
(FOR 3000 PSI UPGRADES ONLY)
Vulcan carrier and Harness Assembly
1. Turn carrier and harness assembly so cylinder band
faces down. MSA logo (on back plate) is on left side.
2. Ensure area is clean.
3. Place NIOSH label over the old NIOSH label in the
same vertical direction.
Black Rhino Carrier and Harness assembly
1. Slide cylinder band free from carrier assembly.
2. Remove the two (2) screws, washers, and tee nuts
holding the top back pad to carrier.
Note: Save the screws and washers. Discard the tee nuts.
The screws and washers can be used for re-assembly.
New tee nuts are supplied with kit.
3. Fold back pad down and away from carrier.
4. Place NIOSH label over the old NIOSH label in vertical
direction, center label on carrier under back pad slot.
Ensure label is visible through slot in back pad.
Note: Place a drop of Loctite #222 thread sealant on all
screws before they are installed.
5. Re-attach back pad to carrier with the old screws,
washers, and new tee nuts. Leak testing must be per-
formed on air mask following disassembly or as part
of a regularly scheduled.
19 TAL 801 (L) Rev. 5 - 10039500