CMM 25-64-01 PBE 22N 8-19-13

Page T-1 25-64-01 Apr 27/2012

D/B/A ESSEX PB&R CORPORATION (CAGE CODE: 0U058)

4150 CARR LANE COURT ST. LOUIS, MO 63119 PHONE: (314) 351-6116 FAX: (314) 351 7181

COMPONENT MAINTENANCE MANUAL

PART NUMBER MR10022N

COMPONENT MAINTENANCE MANUAL

WITH

ILLUSTRATED PARTS LIST

FOR

CREWMEMBER PBE

PART NUMBER: MR10022N

The technical data in this document (or file) is controlled for export under the Export Administration Regulations (EAR), 15 CFR Parts 730-774, ECCN: EAR99. Violations of these laws may be subject to fines and penalties under the Export Administration Act.

D/B/A ESSEX PB&R CORPORATION COMPONENT MAINTENANCE MANUAL


Page RR-1

25-64-01 Aug 19/2013

RECORD OF REVISIONS Revision Number

Issue Date Date Inserted

By Revision Number

Issue Date

Date Inserted

By

1 8/1/2011

2 4/27/2012

3 8/19/2013



Highlights Page-1

25-64-01 Aug 19/2013

TO: HOLDERS OF CREWMEMBER PBE, PART NUMBER: MR10022N COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST.

REVISION NO. 3 DATED AUG 19/2013

HIGHLIGHTS

Pages which have been revised, added, or removed are shown below with the reasons for the changes. Add or remove these pages and record the revision number and the date on the Record of Revisions page.

PAGE DESCRIPTION OF CHANGE

Record of Revisions RR-1 Added Revision No. 3 and date List of Effective Pages LEP-1 Changed for this revision and date LEP-2 Changed for this revision and date 9. Illustrated Parts List Page 47 Changed Part Number for -1 from DP4117 to MR10022N



Page RTR-1

25-64-01 Apr 27/2012

RECORD OF TEMPORARY REVISIONS

Temporary Revision Number

Issue Date Date Inserted/ Inserted By

Date Removed/ Removed By

Date Incorporated



Page SBL-1

25-64-01 Apr 27/2012

SERVICE BULLETIN LIST

Service Bulletin / Revision Number

Issue Date Date Incorporated or No Effect

Title



Page LEP-1

25-64-01 Aug 19/2013

LIST OF EFFECTIVE PAGES

Subject Page Date

Title Page T-1 Apr27/2012

Record of Revision RR-1 Aug19/2013

Record of Temporary Revision RTR-1 Apr27/2012

Service Bulletin SBL-1 Apr27/2012

List of Effective Pages LEP-1 Aug19/2013

LEP-2 Aug19/2013

Table of Contents TOC-1 Apr27/2012

Introduction INTRO-1 Apr27/2012

Description and Operation 1 Apr27/2012

2 Apr27/2012

3 Apr27/2012

4 Apr27/2012

5 Apr27/2012

6 Apr27/2012

7 Apr27/2012

8 Apr27/2012

9 Apr27/2012

10 Apr27/2012

11 Apr27/2012

12 Apr27/2012

13 Apr27/2012

Testing and Fault Isolation 14 Apr27/2012

15 Apr27/2012

16 Apr27/2012

17 Apr27/2012

18 Apr27/2012

19 Apr27/2012

Disassembly 20 Apr27/2012

21 Apr27/2012

Cleaning 22 Apr27/2012

Check 23 Apr27/2012

24 Apr27/2012

25 Apr27/2012

26 Apr27/2012

Repairs / Assembly 27 Apr27/2012

28 Apr27/2012

29 Apr27/2012

30 Apr27/2012

Cleaning 22 Apr27/2012



Page LEP-2

25-64-01 Aug 19/2013

31 Apr27/2012

32 Apr27/2012

33 Apr27/2012

34 Apr27/2012

35 Apr27/2012

36 Apr27/2012

37 Apr27/2012

38 Apr27/2012

39 Apr27/2012

40 Apr27/2012

41 Apr27/2012

42 Apr27/2012

Special Tools, Fixtures, and Equipment 43 Apr27/2012

Illustrated Parts List 44 Apr27/2012

45 Apr27/2012

46 Apr27/2012

47 Aug19/2013

48 Apr27/2012

49 Apr27/2012

50 Apr27/2012

51 Apr27/2012

Storage 52 Apr27/2012



Page TOC-1

25-64-01 Apr 27/2012

TABLE OF CONTENTS

SUBJECT PAGE

Title Page T-1

Record of Revisions RR-1 Record of Temporary Revisions RTR-1 Service Bulletin List SBL-1 List of Effective Pages LEP-1 Table of Contents TOC-1 Introduction INTRO-1 1. Description and Operation 1

2. Testing and Fault Isolation 14

Schematics and Wiring Diagrams N/A

3. Disassembly 20

4. Cleaning 22

5. Check 23

6. Repairs 27

7. Assembly 27

Fits and Clearances N/A

8. Special Tools, Fixtures, and Equipment 43

9. Illustrated Parts List 44

10. Storage 52



Page INTRO-1

25-64-01 Apr 27/2012

INTRODUCTION The manual supplies data and instructions to do maintenance, tests, and repairs on the Essex PB&R Crewmember PBE (Model Number MR10022N) in the shop. The data and procedures are necessary to make sure that the PBE operates satisfactorily, if needed, when returned to service. This manual will be revised as necessary to include current information. It contains:

Technical data for the PBE

Testing and fault isolation procedures

Maintenance and repair procedures for the component

An Illustrated Parts List (IPL) Refer to the Table of Contents to find the page numbers for each section. The IPL figure and item number are used to identify parts in all sections of the manual. The introduction to the IPL tells how to use the IPL. All weights and dimensions in the manual are in English units with metric equivalents in parentheses, unless stated differently. Maintenance Task Oriented Support System (MTOSS) is a numbering system that is utilized in this manual. It is used to separate different maintenance functions that can be performed on the PBE. Unique task/subtask numbers are assigned to each action. The numbering system is an expansion of the ATA three element numbering system, and consists of seven elements. The first three elements are the existing ATA numbers; the fourth element is a three-digit function code which defines the maintenance function being performed; the fifth element is a three-digit number used to create unique numbers for all the tasks or subtasks which are similarly numbered through the first four elements; the sixth element is a three-digit alphanumeric identifier used to uniquely identify differences in configuration; and the seventh element is assigned by the operator to identify airline unique tasks and/or subtasks. Date of Shop Verification by Actual Performance: Completed on 7/30/08 Engineering Technical Review: Completed on 7/28/08 by Kelley Posey, Engineering

Manager, Essex PB&R Corporation



Page 1

25-64-01 Apr 27/2012

1. DESCRIPTION AND OPERATION

A. General Description of Equipment

(1) Purpose of the Equipment

The Essex PB&R Corp. (Essex) Crewmember PBE (Ref. Figure 1 on page

2) is a self-contained, portable, personal breathing device designed to safeguard the wearer from the effects of smoke, carbon dioxide, harmful gases, and oxygen deficiency while managing in-flight fire, smoke or fume emergencies.

The equipment improves the wearer’s visibility in smoke-filled compartments, protects the head and face from melting or dripping plastics, and shields the head against brief exposure to heat and flame. The primary functional component in the Essex Crewmember PBE is a portable hood that contains both a breathable oxygen supply and lithium hydroxide (LiOH) scrubber panels that absorb exhaled carbon dioxide. The hood has a self-fitting neck opening that seals out contaminants, retains the oxygen and keeps the hood inflated during use. The entire unit is hermetically sealed at Essex PB&R Corp. to protect the LiOH scrubber panels from outside air.

(2) Hood Shell Construction

The Essex Crewmember PBE hood is fabricated from a durable, tear-resistant combination of polyimide and PFA films. The hood’s inner surface has an anti-fog coating to improve visibility.

(3) Oxygen System

The Essex Crewmember PBE has two oxygen cylinders. Together they hold a minimum of 36 liters of Aviator Grade oxygen. These cylinders meet SAE Standard AS 8010 for breathing-oxygen purity, and have rupture protection in case of over pressurization.

(4) Service/End-of-Service Indicator

The Essex Crewmember PBE features a battery-powered green and red light Service/End-of-Service Indicator. Mounted slightly below eye level on the left inner side of the hood, this indicator functions as a secondary indicator for monitoring oxygen activation, reassuring the wearer that the equipment is



Page 2

25-64-01 Apr 27/2012

functioning, and signaling when the equipment’s service life is ended. (Ref.

Figure 1 on page 2).

Overall View of Essex Crewmember PBE (As Worn)

Figure 1

Location of End-Of-Service-Indicator

(EOSI)



Page 3

25-64-01 Apr 27/2012

(5) Packaging and Stowage Container

The Essex Crewmember PBE alone weighs 3.2 lbs (1.45 kg). It is folded and packaged in a moisture resistant pouch, and stowed in a protective container made of painted aluminum. A packaged Crewmember PBE is normally installed within 3 ft (.9 m) of each required on-board fire extinguisher. Each airline should receive regulatory approval for installation locations.

(6) Compliance

The Essex Crewmember PBE complies with the requirements of FAA Action Notice A8150.2 and is approved according to FAA TSO-C116 and TSO-C99. The Essex Crewmember PBE is also approved: under BCAR B4-8, United Kingdom – Civil Aviation Authority (CAA) requirements, thereby we are also approved by the European Aviation Safety Agency (EASA); by the Civil Aviation Authority of China (CAAC); and by the National Civil Aviation Agency (ANAC) of Brazil.

(7) Useful Service Life (Warranty Period)

The Essex Crewmember PBE has a 10-year 6-month, warranted, useful service life, beginning from the date of manufacture.

B. Operation Features

(1) Tamper-Evident Seals

To ensure that the Essex Crewmember PBE has not been tampered with, units have tamper-evident seals.

For PBE Model # MR10022N (an internal-mounted stowage case), the tamper-

evident seals are the tamper-evident labels (Type C). (Ref. Fig. 3 on page 6)

(2) Pouch Access The sealed barrier pouch containing the Essex Crewmember PBE is easily

accessed and removed from its stowage container (Ref. para. 1.C. (2) on page

6). A force of approximately 18 - 28 pounds (7.7 – 12.0 kg) will be required to remove the pouch, or to lift the lid & break the tamper-evident seals.

(3) Breathing System

(a) Once the pouch is removed from its container and opened, oxygen flow is

initiated by snapping the two cylinders apart, which in turn activates the



Page 4

25-64-01 Apr 27/2012

flashing green light on the Service/End-of-Service Indicator. One bottle releases oxygen rapidly, whereas the second bottle discharges oxygen slowly. An audible hissing sound and inflation of the unit within (2) minutes indicates the PBE is operating properly.

Once donned, the Essex Crewmember PBE will protect the wearer for up to 15 minutes. Although both bottles will completely discharge in 8 to 10 minutes, enough oxygen will remain for the full, specified 15 minutes of respiratory protection. When the unit deflates to the point where it touches the wearer’s head and face, or when the red light on the Service/End-of-Service Indicator flashes, the unit’s useful life has ended and must be removed.

The Essex Crewmember PBE operates at a positive pressure. The neck Seal acts as a relief valve to prevent excessive pressure from building up inside the hood.

(4) Time Required to Put On and Take Off Hood

A trained user can access and don the hood in approximately 15 seconds. It

can be removed in less than 5 seconds.

(5) Maneuverability During Use

The Essex Crewmember PBE does not restrict or interfere with normal body movements. Even when fully inflated, it is compact enough that the wearer can pass through openings as small as 18 in x 18 in (460 mm x 460 mm).

(6) Carbon Dioxide Control

Special fabric panels inside the hood control carbon dioxide buildup. These panels contain a lithium hydroxide absorbent sealed inside a double walled membrane, which keeps carbon dioxide concentrations at safe levels during the hood’s 15-minute service period.

(7) Interpersonal Communications

Persons wearing the Essex Crewmember PBE can communicate by unaided voice with other people wearing hoods, at a distance of at least 13.1 ft (4 m) away. When using an megaphone or microphone, it may be necessary to pull the skirt of the hood down so the scrubber is below mouth level. Press the phone unit firmly against the hood film in front of the mouth as shown in



Page 5

25-64-01 Apr 27/2012

Figure 2 on page 5, minimizing the gap between the mouth and device.

Megaphone Operation Illustration

Figure 2



Page 6

25-64-01 Apr 27/2012

Tamper-Evident Seals Used on PBE Model # MR10022N

Figure 3

C. Operating Steps

(1) General Sequence of Steps

The normal operating sequence is: access the PBE, open the equipment pouch, activate the system, don the hood, wear it as needed, then remove and dispose of it after use.

(2) Accessing the Essex Crewmember PBE Equipment Pouch

(a) Internal-Mounted Stowage Case (MR10022N)

(Ref. Figure 4 on page 7)

Slide the lid latch/clasp and pull the box lid open sharply. This will break the tamper-evident seals on the container. Approximately 18 to 28 pounds (7.7 to 12.0 kg) of force will be required to lift the lid and break the tamper-evident seals. Grasp the yellow nylon strap and pull the internal barrier pouch assembly from the container.



Page 7

25-64-01 Apr 27/2012

Accessing the Essex PBE Pouch from the Internal-Mounted Stowage Case

Figure 4 – Essex PBE Model Number, MR10022N

Weight 4.7 lbs (2.1 kg)

H W D

Inches 9 3/4 8 15/32 3 1/4

cm 24.77 21.51 8.26



Page 8

25-64-01 Apr 27/2012

(3) Open the Sealed Pouch (Ref. Figure 5 below)

(a) PBE, Model # MR10022N equipment pouches

1) The Tear Open Pouch with the Yellow Nylon Pull Strap is recognizable by the bright red tear strip at the top of the pouch and the yellow pull strap at the bottom of the pouch. To open, grasp the pouch in one hand at either of the small red grip tabs located on each side of the pouch. With the other hand grasp the red tear strip and tear across the pouch in the direction of the arrows. This pouch may be opened from either direction.

NOTE: THE POUCH MAY BE HELD TIGHTLY BETWEEN THE KNEES

WHILE OPENING IT TO PREVENT THE HOOD FROM FALLING TO THE FLOOR.

(b) Remove the hood from the pouch, then discard the pouch.

CAUTION: BEFORE ACTIVATING THE OXYGEN, REMOVE OBJECTS

FROM AROUND THE HEAD (SUCH AS HAIR COMBS, LONG

EARRINGS OR JEWELRY) TO PREVENT THEM FROM

PUNCTURING THE HOOD OR DAMAGING THE NECK SEAL.

Tear Open Pouch with Nylon Pull Strap

Opening the Sealed Barrier Pouch to Remove the Essex PBE

Figure 5



Page 9

25-64-01 Apr 27/2012

(4) Activate the Oxygen Supply (Ref. Figure 6 below).

(a) Before activating the oxygen supply, be sure to position the front of the hood correctly. There are two ways to be sure of this.

1) If visibility permits, locate the amber-colored, transparent, non-metalized

area of the hood. This is the front of the hood. It should not be visible during the activation and donning. The user should see only the metalized area.

2) While grasping the oxygen cylinders (one in each hand), make sure that

the thumbs are pointing in the same direction as the oxygen valves. (These valves are thinner than the cylinders and will be covered with felt.)

Activating the Essex PBE Oxygen Supply - Preparatory to Donning It

Figure 6



Page 10

25-64-01 Apr 27/2012

Unfold the hood far enough to reveal the oxygen cylinders. Grasp each securely, one in each hand, with thumbs pointing toward the valves (the thin end of each bottle).

Sharply snap the oxygen cylinders away from each other. This sharp action pulls on the two cords that trigger the oxygen flow and activates the green light on the Service/End-of-Service Indicator.

NOTE: DO NOT PULL THE OXYGEN CYLINDERS APART SLOWLY. DOING SO WILL INCREASE THE FORCE NECESSARY TO ACTIVATE THE EQUIPMENT.

WARNING: TO AVOID LOSING OXYGEN ONCE THE SYSTEM IS

ACTIVATED, AND TO MINIMIZE THE AMOUNT OF

TOXINS THAT MAY ENTER THE HOOD, DON THE HOOD

PROMPTLY AFTER ACTIVATION.

(5) Don the Activated Hood (Ref. Figure 7 on page 11)

(a) The sharp snapping action required to activate the equipment will reveal the self-fitting elastic neck seal.

(b) Hold the equipment at about waist level. Place both hands inside the neck seal opening, with palms facing each other. Stretch the neck seal open by spreading the hands apart.

(c) Lift up the opened hood with both hands, and then lower it down over the head until it fits securely around the neck.

NOTE: EYEGLASS WEARERS SHOULD FIRST POSITION THE NECK SEAL AGAINST THE BACK OF THE HEAD, THEN PULL THE HOOD FORWARD AND DOWN OVER THE EYEGLASSES.

NOTE: MAKE SURE THAT SHIRT COLLARS OR SCARVES DO NOT INTERFERE WITH THE NECKSEAL.



Page 11

25-64-01 Apr 27/2012

Donning the Activated Essex PBE

Figure 7

WARNING: AFTER DONNING THE HOOD, DO NOT OPEN THE

NECK SEAL EXCEPT TO QUICKLY TUCK IN HAIR,

OR TO ADJUST THE HOOD’S POSITION. HAVE

ANOTHER PERSON HELP IF NEEDED.



Page 12

25-64-01 Apr 27/2012

(d) The equipment is donned correctly if the oxygen cylinders are positioned over the shoulders under each ear and the transparent amber-colored area is facing front.

If the hood is accidentally donned backwards, do not remove it. Instead, rotate the hood until it is properly positioned.

WARNING: IF EITHER OF THE FOLLOWING CONDITIONS

EXIST, REMOVE THE EQUIPMENT AND DISCARD

IT IMMEDIATELY:

(1) THE SOUND OF THE OXYGEN FLOW IS

INAUDIBLE IMMEDIATELY AFTER DONNING.

(2) THE HOOD DOES NOT INFLATE WITHIN 2 TO 3

MINUTES, OR COLLAPSES.

WARNING: DO NOT PASS ALONG AN ACTIVATED HOOD TO

ANOTHER PERSON ONCE IT IS DONNED. THIS

WILL CAUSE OXYGEN TO ESCAPE AND CAN

SUBSTANTIALLY REDUCE PERFORMANCE. (6) Wearing the Hood

Full hood inflation takes from 2 to 3 minutes but the equipment is ready for use immediately. During the first few minutes the oxygen makes a noticeably loud, hissing sound that gradually diminishes. The oxygen stops flowing after 8 to 10 minutes, but enough remains in the hood for a full 15 minutes of usage.

WARNING: IF THE HOOD COLLAPSES AROUND THE FACE AT

ANYTIME, REMOVE IT IMMEDIATELY AND OBTAIN

A NEW ONE.

WARNING: DO NOT APPROACH ANY CLOSER TO A FIRE OR

FLAMES THAN THE NORMAL RANGE OF AN

APPROVED FIRE EXTINGUISHER, SINCE THE USER

WILL ORDINARILY NOT BE WEARING FIRE-

RESISTANT CLOTHING. (a) Observe the flashing green Service/End-of-Service Indicator light inside the

hood, located to the left and just below eye level. When the red light flashes with the green light, or when the hood collapses, move immediately to a safe area and remove the unit.



Page 13

25-64-01 Apr 27/2012

(b) Note that warming and condensation inside the hood may occur. If this interferes with vision, press the hood against the face to wipe away condensation.

(c) Some users may experience mild ear popping as the air pressure inside

the hood gradually increases due to the oxygen flow.

(d) Interphone, megaphone and microphone communication are possible while the hood is still inflating and during its operation. Press the phone device directly against the hood for best operation. Or, place the phone device up against the Adam’s apple.

WARNING: DO NOT REMOVE THE HOOD WHILE NEAR SPARKS

OR OPEN FLAME. SOME RESIDUAL OXYGEN

MAY REMAIN IN BOTH THE HOOD AND HAIR.

(7) Remove and Discard the Hood

Remove the PBE if the hood collapses over the face, or as soon as the red light in the Service/End-of-Service indicator comes on, or immediately after the emergency is under control, whichever comes first.

(a) Leave the area of the emergency before attempting to remove the hood.

(b) To remove the hood, insert both hands under the neck seal, beneath the chin. Lift the hood up and out to clear the face.

NOTE: EYEGLASS WEARERS SHOULD FIRST INSERT BOTH HANDS UNDER THE NECK SEAL, THEN PULL THE HOOD FORWARD AND OUTWARD, LIFTING IT UP OVER THE HEAD TO AVOID DISLODGING THE EYEGLASSES.

(8) Dispose of Equipment Properly

WARNING: DO NOT CUT INTO THE WHITE PANELS AROUND THE

COLLAR OR UP THE BACK OF THE HOOD. THIS MAY

EXPOSE LITHIUM HYDROXIDE AND LITHIUM CARBONATE,

WHICH CAN IRRITATE THE SKIN AND BREATHING

PASSAGES.

Follow these steps in properly disposing of spent equipment.

(a) Cut the neck seal into four quadrants.



Page 14

25-64-01 Apr 27/2012

(b) Cut a hole in the amber-colored transparent film area at least 5 inches (12.7 cm) across.

(c) If the oxygen system has not yet been activated, do so before disposing of the equipment.

1) Handle the oxygen disposal in an area where there is no potential

danger from sparks or other fire hazards.

2) After equipment has been activated, leave it alone for at least one hour, so that all residual oxygen will dissipate.

(d) Dispose of the hood in compliance with federal, state and local EPA

regulations. Contact the appropriate agency for proper disposal procedures. The white scrubber panels contain about .44 pounds (200 grams) of lithium hydroxide and/or lithium carbonate.

D) Leading Particulars Part Number: MR10022N Packaged Weight 4.7 pounds (2.1 kg)

PBE Alone Weight (w/o Packaging) 3.2 pounds (1.45 kg)

Packaged Size 9 ¾” H x 8 15/32” W x 3 ¼” D

(24.7 cm H x 21.5 cm W x 8.26 cm D)

Shelf Life 10 years 6 months from Date of Mfg.

Donning Time Less than 15 seconds

Operating Temperature Range +5°F to +122°F (-15°C to +50°C)

Storage Temperature Range -20°F to +185°F (-29°C to +85°C)

2. TESTING AND FAULT ISOLATION A. General Serviceability Inspection

Inspection and inspection frequency of PBE’s in stowage containers should be in accordance with your governing regulatory authority and your airline operating procedure. To determine serviceability, the PBE will be inspected by the following indicators: replace by date label, tamper-evident seals, and humidity indicator.



Page 15

25-64-01 Apr 27/2012

B. Methods of Serviceability Inspection

(1) Replace by Date Label: The first step is to inspect the date on the replace by

date label. If the replace by date has not been exceeded proceed to the next

inspection step. If the replace by date has been exceeded, the unit must be immediately replaced.

(2) Tamper-Evident Seals: Tamper-evident seals are the second step for determining serviceability of the PBE. If the tamper seals are in place and undamaged proceed to the next inspection step. If the tamper seals are not in place, broken, or damaged, proceed to the next inspection step but follow the sequence on the inspection flow chart in Figure 9 on page 16.

(3) Humidity Indicator: The humidity indicator represents the third step of inspection. The purpose of the humidity indicator is to show that moisture has

gotten inside of the barrier pouch, and may come in contact with the lithium

hydroxide scrubbers inside of the hood. Please see Figure 8 below that illustrates acceptance criteria.

Blue Indicator: Unit is Acceptable Pink Indicator: Remove Unit from

Service within one (1) calendar day

Humidity Indicator Acceptance Criteria

Figure 8

The method of inspection for the PBE can be found in an easy to read flow chart provided

in Figure 9 on page 16. Deviation from the recommended inspection method for

your particular PBE is not covered by the factory warranty, and is the sole

responsibility of the operator.



Page 16

25-64-01 Apr 27/2012

ALL TAMPER SEALS

UNDAMAGED

ONE TAMPER SEAL DAMAGED

ALL TAMPER SEALS DAMAGED

INSPECT THE HUMIDITY INDICATORS’S COLOR

(REF.FIG. 8)

REPLACE DAMAGED TAMPER SEALS AS SOON AS POSSIBLE

COLOR: BLUE

COLOR: PINK

REMOVE UNIT FROM SERVICE WITHIN

ONE CALENDAR DAY

INSPECTION COMPLETE

INSPECT CONDITION OF TAMPER SEALS

INSPECTION COMPLETE

REPLACE DAMAGED TAMPER SEAL AS SOON

AS POSSIBLE

INSPECT DATE ON THE REPLACE BY DATE LABEL

DATE NOT EXCEEDED

DATE EXCEEDED

REMOVE UNIT FROM SERVICE IMMEDIATELY

Inspection Procedure Flow Chart

Figure 9



Page 17

25-64-01 Apr 27/2012

C. Statement of Warranty for Protective Breathing Equipment (PBE)

Essex Industries D/B/A Essex PB&R Corporation (hereinafter referred to as Essex). warrants that: (1) The Essex Crewmember PBE (hereinafter referred to as the “unit”) meets the requirements of FAA TSO-C116 and TSO-C99 and CAA; and (2) The Essex Crewmember PBE is, and will remain free from defects in material and workmanship, whether patent or latent, for up to the replace by date which is a period of ten (10) years and six (6) months from the date of manufacture when properly stowed aboard aircraft in containers supplied or approved by Essex.

For those units equipped with a humidity indicator, the loss of vacuum in the inner packaging does not render the PBE unserviceable. Units with barrier pouches that have lost vacuum remain serviceable as long as the humidity indicator remains blue. Although if a unit is found to have a damaged barrier pouch, e.g. cut, puncture or other damage, the unit should be pulled from service and repaired.

The liability of Essex for any defect in any unit, and the sole and exclusive remedy of the buyer, shall be limited to the repair or replacement of the defective unit, or a refund of the original purchase price (pro-rated in proportion to the ten (10) year and six (6) month warranty) at the sole discretion of Essex. The obligation to repair, replace, or provide a pro-rated refund shall terminate ten (10) years and six (6) months after the date of manufacture of the unit.

This warranty is in lieu of all other warranties and representations, expressed or implied, and all other obligations and liabilities of Essex. Correction of defects, in the manner and for the period of time provided above, shall constitute fulfillment of all liabilities of Essex whether based on warranty, tort, contract or otherwise. Under no circumstances shall Essex be liable for any punitive, special, incidental or consequential damages. This warranty shall not apply to any unit that has been stowed in an unauthorized container, or which has been subject to misuse due to negligence or accident, or the failure to use the unit in accordance with the User Reference and Procedures Manual supplied by Essex.

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL WARRANTIES,

EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY

IMPLIED WARRANTY OF MERCHANTABILITY, NON-INFRINGEMENT, OR

FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY OTHER OBLIGATION

ON THE PART OF ESSEX.



Page 18

25-64-01 Apr 27/2012

D. Return Procedures

(1) Before returning any unit for repair, replacement or evaluation, call Essex Industries D/B/A Essex PB&R Corporation at (314) 351-6116, or at 1-800-296-7587 (U.S. only) to obtain a Return of Material Number (RMA). To expedite handling, supply the following information:

(a) Product Model Number

(b) Quantity to be returned

(c) Reason(s) for return

(2) Address all shipments to: Essex Industries

D/B/A Essex PB&R Corporation 4150 Carr Lane Court St. Louis, MO 63119

(3) Freight on all shipments is to be prepaid.

(4) Shipping instructions will vary depending on mode of shipment.

(a) For domestic or international air shipments:

(i) Bill of lading description (Ref. Figure 10 on page 19 for an example of a complete shipper’s declaration for dangerous goods):

Life saving appliances, not self-inflating, UN3072

(ii) Hazard labeling (IATA/ICAO): three hazard labels are required:

Miscellaneous Class 9

(iii) Hazard Marking (IATA/ICAO):

Life saving appliances, not self-inflating, UN3072

(b) For domestic highway shipments:

(i) Bill of lading description:

Life-saving appliances, not self-inflating, UN3072



Page 19

25-64-01 Apr 27/2012

(ii) Hazard labeling (DOT): None

(iii) Hazard Marking (DOT):

Life-saving appliances, not self-inflating, UN3072

Proper

Shipping Name

Class or Division

UN or ID Number

Net Qty’s

Packing

Instructions

Life saving

appliances, not self-inflating, UN3072

9

UN3072

_*_ x 0.248 kg

955

* Enter number of units shipped to calculate total net quantity.

Example of Complete Shipper’s Declaration for Dangerous Goods

Figure 10



Page 20

25-64-01 Apr 27/2012

3. DISASSEMBLY

A. Table of Materials, Tools, and Equipment:

Name Description Quantity Copy of each Units Original PBE Hood Traveling Docket

Essex PB&R Customer Service can supply this document. (Form # QR-4.10.10035)

1

New PBE Hood Traveling Docket

Essex PB&R Customer Service can supply this document. (Form # QR-4.10.10035)

1

New Maintenance Repair Data Log

Essex PB&R Customer Service can supply this document. (Form # QR- 4.10.10035-1)

1

Large Zip-Lock Bag Large Zip-Lock Bag 18” x 24” (45.7 cm x 61 cm)

1

Barcode Printer w/ PC loaded with Barcode Printing Software

Intermec Model PM4i with Loftware – On Demand Print Version Software or equivalent.

1

External E-Ring Pliers For Shaft Diameter of 9/32” (.714 cm) 1

HVAC Equipment to maintain 20% RH Max.

Required HVAC Equipment to maintain work and storage area at 20% RH Max.

1

Note: Equivalent substitutes may be used.

B. Refer to Section 9. Illustrated Parts List for identification of parts.

Task 25-64-01-000-801 C. Disassembly Procedure: (Figures 1, 2, & 3 / Task 25-64-01-990-801)

1) Contact Essex PB&R Customer Service @ 314-351-6116 and request that a copy of the original PBE Hood Traveling Docket, form # QR-4.10-10035 for each unit being repaired be e-mailed or faxed to the repairman performing the repair. Supply each unit(s) Serial Number.

2) Once a hard copy of the original docket for each unit has been generated, the

repair of the unit can begin.

3) Staple a new PBE Hood Traveling Docket, form # QR-4.10-10035 to the front side of the copy of the original docket and prepare an identical Serial Number label and apply it to the top right hand corner of the new docket.

4) Staple or apply a Maintenance Repair Data Log (if one is not already present),

form # QR-4.10.10035-1 onto the back of the original docket. 5) As the unit is disassembled, keep all of the disassembled parts together in a

large zip lock type bag along with the unit’s Dockets and Repair Log.



Page 21

25-64-01 Apr 27/2012

6) Remove Compact Barrier Pouch Assembly (Fig. 1, Item 3) from the Stowage Bracket Sub-Assembly (Fig. 1, Item 2).

7) Visually inspect Stowage Bracket Sub-Assembly (Fig. 1, Item 2) for defects

such as large dents, deep scratches, illegible labels, tears, broken hinges, broken rivets, missing felt liners, etc. If unacceptable, tag with a reject tag and segregate. If acceptable, set aside in zip-lock bag for cleaning. If not acceptable, discard and get new Stowage Bracket Sub-Assembly (Fig. 1, Item 2) from Stock Spares, and place in zip-lock bag.

8) Inspect the condition of the Compact Barrier Pouch Assembly (Fig. 1, Item 3)

and its humidity indicator. Assign one of the following disposition codes to the unit:

9) PR – Pouch Repair – Unit for repair that the Compact Barrier Pouch Assembly

(Fig. 1, Item 3) has been damaged (cut, torn, and/or punctured) and has lost vacuum, yet the humidity indicator remains blue in color. Record the disposition code PR onto the Maintenance Repair Data Log, form # QR-4.10.10035-1, Block # 5.

10) HR – Humidity Indicator Repair – Units for repair with humidity indicators that

have turned from blue to pink in color. Record the disposition code HR onto the Maintenance Repair Data Log, form # QR-4.10.10035-1, Block # 5.

Note: The remaining disassembly procedure steps are required to be

performed in an area were the relative humidity is controlled to a

maximum of 20%.

11) Tear off the red tear strip of the Compact Barrier Pouch Assembly (Fig. 1, Item 3) to gain access to the Hood/Neck Seal Assembly (Fig. 2, Item 4) within.

12) Pull the Hood/Neck Seal Assembly (Fig. 2, Item 4) out of the Compact Barrier

Pouch Assembly (Fig. 1, Item 3) and discard the barrier pouch. The barrier pouch cannot be re-used once it is torn open.

13) Gently unfold the Hood/Neck Seal Assembly (Fig. 2, Item 4).

14) The first step to disassemble the Hood/Neck Seal Assembly (Fig. 2, Item 4) is

to remove the two Oxygen Dispenser Assemblies (Fig. 3, Item 6) from the unit. One Oxygen Dispenser Assembly (Fig. 3, Item 6) is held in place with an

External Retaining Ring (Fig. 3, Item 9) and the other is held in place with a screwed on End of Service Indicator (Fig. 3, Item 11)



Page 22

25-64-01 Apr 27/2012

15) Remove the 6” long piece of Tygon Tubing (Fig. 3, Item 10) from the end of the fitting on one of the Oxygen Dispenser Assemblies (Fig. 3, Item 6) and set aside in the zip-lock bag for re-use.

16) Using retaining ring pliers, remove the External Retaining Ring (Fig. 3, Item 9)

from inside the Hood/Neck Seal Assembly (Fig. 2, Item 4) that secures one of the Oxygen Dispenser Assemblies (Fig. 3, Item 6) and discard External Retaining Ring (Fig. 3, Item 9).

17) Remove the Oxygen Dispenser Assembly (Fig. 3, Item 6), Oxygen Nozzle

Wrap (Fig. 3, Item 7), and Plastic Washer (Fig. 3, Item 8) and set aside in the zip –lock bag for re-use.

18) Remove the End of Service Indicator (EOSI) (Fig. 3, Item 11) from its hook &

loop fastener affixed to the inside wall of the Hood/Neck Seal Assembly (Fig. 2, Item 4). Slide the EOSI (Fig. 3, Item 11) down and behind the Front Scrubber (Fig. 3, Item 3) until it is free.

19) Unscrew the EOSI (Fig. 3, Item 11) from the remaining Oxygen Dispenser

Assembly (Fig. 3, Item 6) by turning by hand counter clockwise and set-aside in the zip-lock bag for checking.

20) Remove the Oxygen Dispenser Assembly (Fig. 3, Item 6) and set aside in the

zip-lock bag for checking.

21) Set aside the Hood/Neck Seal Assembly (Fig. 2, Item 4) assembly in the zip-lock bag for checking.

4. CLEANING


Name Description Quantity

Degreaser Any Commercial Grade Degreaser (Krud Cutter®, Goo Gone®, etc.)

A/R

Glass Cleaner Any Commercial Grade Glass Cleaner (Windex®, Glass Plus®, etc.)

A/R

Note: Equivalent substitutes may be used. Task 25-64-01-100-801

B. Cleaning Procedure: (Figures 1, 2, & 3 / Task 25-64-01-990-801)



Page 23

25-64-01 Apr 27/2012

1) The only part that requires cleaning is a Stowage Bracket Sub-Assembly (Fig.

1, Item 2) that is being re-used. New Stowage Bracket Sub-Assemblies are not required to be cleaned (they already are).

2) Remove the Instruction Label (Fig. 1, Item 5), two (2) Pull Open Labels (Fig. 1,

Item 6), and the PBE-TSO & CAA Label (Fig. 1, Item 7) from the Stowage Bracket Sub-Assembly (Fig. 1, Item 2). Use Degreaser to remove all of the residual adhesive and scuff marks from outer surface of the metal portion of the Stowage Bracket Sub-Assembly (Fig. 1, Item 2). Use Glass Cleaner to remove any residue from the clear plastic window of the Stowage Bracket Sub-Assembly (Fig. 1, Item 2).

3) Set aside cleaned Stowage Bracket Sub-Assembly (Fig. 1, Item 2) in zip-lock

bag for re-use.

5. CHECK



Beaker 100 ml Beaker 1

Punch 5/8” (1.59 cm) diameter Punch 1

Distilled Water Commercial Grade A/R

Hand Tweezers Commercial Grade 1

Electronic Balance 500 g capacity, .01 g readability 1

Titrator Mettler Model DL50 or equivalent 1

Pressure Test Fixture Specialized Tooling, which can be purchased from Essex PB&R Corporation. (P/N: C-P-8259)

1

Compressed nitrogen or clean, dry compressed air

Used to inflate hoods and supply internal pressure for leak testing.

NA

Acrylic Tape Clear 1” wide Acrylic Tape A/R



1

Cut Cable Tie Essex PB&R can supply this Cable Tie (P/N: PLT1.5I-M)

1

Note: Equivalent substitutes may be used. Task 25-64-01-200-801

B. Check Procedure: (Figures 1, 2, & 3 / Task 25-64-01-990-801)



Page 24

25-64-01 Apr 27/2012

Task 25-64-01-200-001 1. Scrubber Test – If the disposition code for the unit to be repaired is PR

(humidity indicator remains blue in color) – this test is not required. If the disposition code is HR (humidity indictor is pink in color) – this test is required.

Note: The Scrubber Test procedure steps are required to be performed in an

area were the relative humidity is controlled to a maximum of 20%.

(a) Remove one of the two Front Scrubbers (Fig. 3, Item 3) form the Hood/Neck Seal Assembly (Fig. 2, Item 4).

(b) Place a plastic 100 ml beaker onto the balance and tare it to zero grams.

(c) Using a punch, cut a 5/8” (1.59 cm) diameter dot from the center of the

Front Scrubber (Fig. 3, Item 3).

(d) Place the dot into the tared 100 ml beaker and record its weight in grams.

(e) Add approximately 50 ml of distilled water to the 100 ml beaker and dot.

(f) Using tweezers shake the dot and separate the upper and lower layers of filter media from the Lithium Hydroxide. Discard the layers of filter media.

(g) Attach the 100 ml beaker to the titration fixture.

(h) Operate the titrator to perform the titration test.

(i) Enter the P and M Values obtained from the Titration Test and the

previously recorded dot weight in grams into the following equation:

Percent Lithium Carbonate (% Li2CO3) %Li2CO3=(((((M value – P value)/1000) / 2) x 73.89) / Sample Wt in gms) x 100

(j) If the % Lithium Carbonate is less than or equal to 7%, the sample is

acceptable. If the % Lithium Carbonate is greater that 7%, the sample is rejected.

(k) If the test is acceptable, only replace the Front Scrubber (Fig. 3, Item 3)

used for the sample, with an approved, new Front Scrubber (Fig. 3, Item 3). Pull from Spare Stock one new Front Scrubber (Fig. 3, Item 3).

(l) If the test is rejected, remove remaining Front Scrubber (Fig. 3, Item 3),

Top Scrubber (Fig. 3, Item 4), and Rear Scrubber (Fig. 3, Item 5) from the



Page 25

25-64-01 Apr 27/2012

unit and replace all of them with approved, new scrubbers. Pull from Spare Stock two new Front Scrubbers (Fig. 3, Item 3), one new Top Scrubber (Fig. 3, Item 4), and one new Rear Scrubber (Fig. 3, Item 5).

Task 25-64-01-200-002

2. Hood Pressure Test Procedure

Note: The Hood Pressure Test procedure steps are required to be performed

in an area were the relative humidity is controlled to a maximum of 20%.

(a) All repaired units are to be subjected to the Hood Pressure Test. (b) Orient the Hood/Neck Seal Assembly (Fig. 2, Item 4) with the hood shell

on top and the neck seal towards the bottom.

(c) Turn the turtleneck portion of the neck seal down.

(d) Stretch the turtleneck over the post of the fixture.

(e) Slide up the fixture’s o-rings over the turtleneck to affix the neck seal to the post.

(f) Slowly open the pressure valve until 4” of H2O (9.96 mbar) is attained.

(g) Close the pressure valve.

(h) Set the timer for 2 minutes and start it.

(i) At the end of 2 minutes, record on the docket the internal pressure in the

hood.

(j) If the pressure stays at or above 3.2” of H2O (8.0 mbar), the assembly is accepted.

(k) Remove the assembly from the test fixture and place into zip –lock bag for

re-use.

(l) If the pressure falls below 3.2” of H2O (8.0 mbar), the assembly is to be rejected, and a new Hood Shell / Neck Seal Sub-Assembly (Fig. 2, Item 4) is to be used. Remove all of the scrubbers from the rejected hood and set aside in the zip-lock bag for re-use.

(m) For units that require a new Hood Shell / Neck Seal Sub-Assembly (Fig. 2,

Item 4) – cut off the serial number label from the rejected hood and tape it



Page 26

25-64-01 Apr 27/2012

onto the new Hood Shell / Neck Seal Sub-Assembly (Fig. 2, Item 4). The serial number label is to cover the new hoods serial number label.

Note: The serial number label is located on the inside skirt of the hood, below the neck seal.

Task 25-64-01-200-003

3. Oxygen Bottle Assembly Weight Test (a) Tare the balance to zero. (b) Place each Oxygen Dispenser Assembly (Fig. 3, Item 6) onto the balance,

one at a time.

(c) Add a cut cable tie (because the original weight included a cable tie).

(d) Record the weight.

(e) If the recorded weight is within +/- .2 grams of the weight written on the label of the bottle, the assembly is acceptable and can be re-used.

(f) If the recorded weight is not within +/- .2 grams of the weight written on the

label of the bottle, the assembly is to be rejected, and a new Oxygen Dispenser Assembly (Fig. 3, Item 6) is to be used. Disposal of the rejected

Oxygen Dispenser Assembly (Fig. 3, Item 6) is to be per 1.C.8.c on page

13 of this Component Maintenance Manual.

Task 25-64-01-200-004 4. End of Service Indicator (EOSI) Test

(a) Using a 3/16” diameter, flat ended pin, push out the Switch Head Plug from the Switch Housing of the EOSI (Fig. 3, Item 11).

(b) Examine the Indicator Lamps of the EOSI (Fig. 3, Item 11).

(c) If the Green Indicator Lamp is flashing on and off, re-insert the Switch

Head Plug by hand into the Switch Housing and set aside for re-use.

(d) If the Green Indicator Lamp is not flashing on and off, reject and discard the EOSI (Fig. 3, Item 11) and obtain a new EOSI from Spare Stock.

5. Report of Defects or Unairworthy Conditions

(a) If any serious failure, malfunction, or defect is discovered during the repair of the component, the technician shall notify the Quality Assurance Manager of Essex PB&R Corporation immediately @ 314-351-6116.



Page 27

25-64-01 Apr 27/2012

6. REPAIRS

Task 25-64-01-300-801 A. Repairs (other than minor ones, as detailed below) are limited to replacement of worn or damaged components. (Figures 1, 2, & 3 / Task 25-64-01-990-801)

2) Minor maintenance repairs do not require the PBE to be removed from its vacuum-sealed barrier pouch.

3) Refitting Broken, Torn or Missing Tamper Seals (Fig. 1, Item 4):

(a) Remove and discard the torn, broken Tamper Seal(s) (Fig. 1, Item 4). (b) Remove any residual adhesive from the Stowage Bracket Sub-Assembly

(Fig. 1, Item 2) to provide a clean, dry surface.

(c) Position and affix the new Tamper Seal(s) (Fig. 1, Item 4) so that the perforation on the label aligns with the top edge of the lid. There should be about 0.5 in (13 mm) clearance between the Tamper Seals (Fig. 1, Item 4) and the hinge side of the Stowage Bracket Sub-Assembly (Fig. 1, Item 2).

7. ASSEMBLY

A. General

1) This procedure has the data necessary to assemble the component.

2) The assembly procedure is required to be performed in an area were the

relative humidity is controlled to a maximum of 20%.

3) Refer to Section 9. Illustrated Parts List for identification of parts.

B. Materials

1) The following list of spare parts are required to be stocked in order to perform the assembly procedure on the Essex Crewmember PBE, Model # MR10022N, all of which can be purchased from Essex PB&R Corporation:

Part Name Part Number Qty Required

per PBE

*Top Scrubber (Fig. 3, Item 4) CP2116 1

*Front Scrubber (Fig. 3, Item 3) DP2115 2



Page 28

25-64-01 Apr 27/2012

*Rear Scrubber (Fig. 3, Item 5) DP2114 1

*Compact Barrier Pouch Sub-Assembly

(Fig. 2, Item 2)

CP2130 1

Hood Shell / Neck Seal Sub-Assembly (Fig. 2, Item 4)

DP2119 1

Oxygen Dispenser Assembly (Set) (Fig. 3, Item 6)

AP3208-8 1

Stiffener (Fig. 2, Item 3) AP4119 1

External Retaining Ring (Fig. 3, Item 9) 98410A112 1

End of Service Indicator (Fig. 3, Item 11) CP3209 1

Anti-Fog Solution SA67 A/R

Stowage Bracket Sub-Assembly (Fig. 1, Item 2)

DP4116 1

Tamper Evident Seals (Fig. 1, Item 4) BP4231 2

PBE – TSO & CAA Label (Fig. 1, Item 7) BP4243 1

Instruction Label (Fig. 1, Item 5) BP4201 1

Pull Open Labels (Fig. 1, Item 6) AP4242 1

Red Cloth (Duct) Tape 2” wide (5.1 cm) (Fig. 2, Item 5)

223 Red A/R

Plastic Washer (Fig. 3, Item 8) AP4117 1

Button Plug w/ Flush Head (Fig. 1, Item 8) BPF375 4

Oxygen Nozzle Wrap (Fig. 3, Item 7) CS1101 2

Commercial Grade - Corn Starch N/A A/R

Tygon Tubing, 3/16” ID x 5/16” OD x 6” long (.48 cm ID x .79 cm OD x 15.24 cm long) (Fig. 3, Item 10)

R3603 1

Masking Tape – Painters Grade, 1” wide (2.54 cm)

N/A A/R

* These parts are required to be stored in a low humidity environment

maintained at 20% maximum.


C. Tools, Fixtures, and Equipment

1. Refer to the table below for a list of tools, fixtures and equipment necessary to assemble the component. Note: Equivalent substitutes may be used.



Page 29

25-64-01 Apr 27/2012




1

Hood Shell Jig (Scrubber Installation)

Specialized Tooling, which can be purchased from Essex PB&R Corporation. (P/N: D-P-8258)

1

External E-Ring Pliers For Shaft Diameter of 9/32” 1

Heat Gun Varitemp, Model VT-750C or equivalent 1

Small Side Cutters Commercial Grade 1

Barrier Pouch Vacuum Sealing Fixture

Specialized Tooling, which can be purchased from Essex PB&R Corporation. (P/N: B-P-8257)

1

Vacuum Heat Sealer 1/8” to 3/8” (.32 cm to .95 cm) Heat Seal Width w/ .08 mPA minimum vacuum

1

Notching Tool Specialized Tooling, which can be purchased from Essex PB&R Corporation. (P/N: 45N Punch with Notch Design No. 28)

1

Task 25-64-01-400-801 D. Assembly Procedures: (Figures 1, 2, & 3 / Task 25-64-01-990-801)

For units that were Disposition Coded as HR:

1) Place the unit onto the assembly hood shell jig fixture so as the neck seal portion is facing the operator.

2) Insert the assembly ring into the neck seal opening.

3) Re-install the scrubbers as required.

4) For units that only required one Front Scrubber (Fig. 3, Item 3) to be replaced

– affix the hook fasteners on the hood with the corresponding loop fasteners on the Front Scrubber (Fig. 3, Item 3).

5) For units that require that all new scrubbers are to be installed – affix the hook

fasteners on the hood with the corresponding loop fasteners on the scrubbers (one Rear Scrubber (Fig. 3, Item 5), one Top Scrubber (Fig. 3, Item 4) and two Front Scrubbers (Fig. 3, Item 3)).

6) If the units was required to have a new Hood Shell / Neck Seal Sub-Assembly

(Fig. 2, Item 4) – apply anti-fog agent to the internal viewing portion of the hood using a damp applicator.



Page 30

25-64-01 Apr 27/2012

7) Apply light coat of cornstarch to inside and outside surfaces of the Neck Seal.

8) Remove the assembly ring, then remove the Hood/Neck Seal Assembly (Fig. 2, Item 4) from the assembly fixture.

9) Install the low flow Oxygen Dispenser Assembly (Fig. 3, Item 6) (labeled as

P/N 8201321000-2) by first re-installing the Oxygen Nozzle Wrap (Fig. 3, Item 7) over the fitting.

10) Then insert the bottle portion of the Oxygen Dispenser Assembly (Fig. 3, Item

6) into the yellow sling, then insert the fitting thru the hole in the reinforcement of the neck seal.

11) Install a Plastic Washer (Fig. 3, Item 8) over the fitting.

12) Using retaining ring pliers, install the External Retaining Ring (Fig. 3, Item 9)

into the groove of the fitting just above the Plastic Washer (Fig. 3, Item 8).

13) Install 6” Tygon Tubing (Fig. 3, Item 10) by hand down over the end of the fitting.

14) Tuck 6” Tygon Tubing (Fig. 3, Item 10) in behind the Rear Scrubber (Fig. 3,

Item 5) (between the Hood and the outside of the Rear Scrubber).

15) Install the high flow Oxygen Dispenser Assembly (Fig. 3, Item 6) (labeled as P/N 8201321000-7) by first re-installing the Oxygen Nozzle Wrap (Fig. 3, Item 7) over the fitting.



17) Screw on, to hand tight, the Switch Housing of the EOSI (Fig. 3, Item 11) onto

the fitting of the –7 Oxygen Dispenser Assembly (Fig. 3, Item 6).

18) Tuck the EOSI (Fig. 3, Item 11) under the Front Scrubber (Fig. 3, Item 3) and affix loop fastener on back of EOSI (Fig. 3, Item 11) with the corresponding hook fastener on the hood.

19) If new Oxygen Dispenser Assemblies (Fig. 3, Item 6) are used, cut the cable

tie using side cutters and discard cable tie.

20) Wrap Oxygen Nozzle Wraps (Fig. 3, Item 7) around Actuators of Oxygen Dispenser Assembly (Fig. 3, Item 6) and hold in place with a 2” long piece of



Page 31

25-64-01 Apr 27/2012

masking tape.

21) Insert new Stiffener (Fig. 2, Item 3) down into Barrier Pouch Sub-Assembly (Fig. 2, Item 2).

22) Fold unit by grasping the top of the Hood/Neck Seal Assembly (Fig. 2, Item 4)

and fold sides together on both sides of the metallizing. Fold top towards bottom of hood, then fold unit in half. Turn unit over onto metallizing, and pull point under pull string of Oxygen Dispenser Assemblies (Fig. 3, Item 6). Fold Oxygen Dispenser Assemblies (Fig. 3, Item 6) together to package into Barrier Pouch Sub-Assembly (Fig. 2, Item 2).

23) Insert folded unit into new Barrier Pouch Sub-Assembly (Fig. 2, Item 2).

24) Place unit into Vacuum Heat Sealer and affix sides with Toggle Clamps.

25) Operate Vacuum Heat Sealer.

26) Inspect for acceptable heat seal (no creases, or foreign material in heat seal).

27) Set vacuum-sealed unit aside for 24 hours minimum.

28) After 24 hours minimum, inspect Compact Barrier Pouch Assembly (Fig. 1,

Item 3) to determine if the unit has retained its vacuum seal.

29) If yes, proceed with assembly procedure. If no, remove unit from barrier pouch and repeat steps 23 thru 28.

30) Apply 2” wide Red Tape (Fig. 2, Item 5) across recent heat sealed end of

Compact Barrier Pouch Assembly (Fig. 1, Item 3) as detailed below.

31) Using Notching Tool, cut two (2) notches into Yellow Arrow Labels of Compact Barrier Pouch Assembly (Fig. 1, Item 3) as detailed below.



Page 32

25-64-01 Apr 27/2012

32) Apply Serial Number Label and Replace By Date Label to the Compact Barrier

Pouch Assembly (Fig. 1, Item 3) as detailed below.



Page 33

25-64-01 Apr 27/2012

33) Affix new labels onto Stowage Bracket Sub-Assembly (Fig. 1, Item 2) as

detailed below.

34) Apply new labels to the corresponding locations on the PBE TSO & CAA Label

(Fig. 1, Item 7), P/N B-P-4243: Model Number Label (MR10022N); Manufactured By / Serial # Label; Replace by Date Label (use original replace by date); and Date of Manufacture Label (use original manufacture date). Reference Figure 4 on page 7 of this manual.

35) Install Compact Barrier Pouch Assembly (Fig. 1, Item 3) into Stowage Bracket

Sub-Assembly (Fig. 1, Item 2) so as humidity indicator is visible thru clear inspection window.

36) Apply Tamper Seals (Fig. 1, Item 4) onto Stowage Bracket (Fig. 1, Item 2) as

detailed in above drawing.



Page 34

25-64-01 Apr 27/2012

For units that were Disposition Coded as PR:

1) Place the unit onto the assembly hood shell jig fixture so as the neck seal portion is facing the operator.

2) Insert the assembly ring into the neck seal opening. 3) If the units was required to have a new Hood Shell / Neck Seal Sub-Assembly

(Fig. 2, Item 4) – apply anti-fog agent to the internal viewing portion of the hood using a damp applicator.

4) Apply light coat of cornstarch to inside and outside surfaces of Neck Seal.

5) Remove the assembly ring, then remove the Hood/Neck Seal Assembly (Fig.

2, Item 4) from the assembly fixture. 6) Install the low flow Oxygen Dispenser Assembly (Fig. 3, Item 6) (labeled as



6) into the sling, then insert the fitting thru the hole in the reinforcement of the neck seal.

8) Install a Plastic Washer (Fig. 3, Item 8) over the fitting of the Oxygen

Dispenser Assembly (Fig. 3, Item 6). 9) Using retaining ring pliers, install the External Retaining Ring (Fig. 3, Item 9)

into the groove of the fitting just above the Plastic Washer (Fig. 3, Item 8). 10) Install 6” Tygon Tubing (Fig. 3, Item 10) by hand down over the end of the

fitting of the Oxygen Dispenser Assembly (Fig. 3, Item 6). 11) Tuck 6” Tygon Tubing (Fig. 3, Item 10) in behind the Rear Scrubber (Fig. 3,

Item 5) (between the hood and the outside of the Rear Scrubber ). 12) Install the high flow Oxygen Dispenser Assembly (Fig. 3, Item 6) (labeled as






Page 35

25-64-01 Apr 27/2012

14) Screw on, to hand tight, the Switch Housing of the EOSI (Fig. 3, Item 11) onto

the fitting of the –7 Oxygen Dispenser Assembly (Fig. 3, Item 6). 15) Tuck the EOSI (Fig. 3, Item 11) under the Front Scrubber (Fig. 3, Item 3) and

affix loop fastener on back of EOSI (Fig. 3, Item 11) the corresponding hook fastener on the hood.

16) If new Oxygen Dispenser Assemblies (Fig. 3, Item 6) are used, cut the cable

tie using side cutters and discard the cut cable tie. 17) Wrap Oxygen Nozzle Wraps (Fig. 3, Item 7) around Actuators of the Oxygen

Dispenser Assembly (Fig. 3, Item 6) and hold in place with a 2” long piece of masking tape.

18) Fold unit by grasping the top of the Hood/Neck Seal Assembly (Fig. 2, Item 4)

and fold sides together on both sides of the metallizing. Fold top towards bottom of hood, then fold unit in half. Turn unit over onto metallizing, and pull point under pull string. Fold Oxygen Dispenser Assemblies (Fig. 3, Item 6) together to package into barrier pouch.

19) Insert new Stiffener (Fig. 2, Item 3) down into Compact Barrier Pouch Sub-

Assembly (Fig. 2, Item 2). 20) Insert unit down into new Compact Barrier Pouch Sub-Assembly (Fig. 2, Item

2). 21) Place unit into Vacuum Heat Sealer and affix sides with Toggle Clamps. 22) Operate Vacuum Heat Sealer. 23) Inspect for acceptable heat seal (no creases, or foreign material in heat seal). 24) Set vacuum sealed unit aside for 24 hours minimum. 25) After 24 hours minimum, inspect Compact Barrier Pouch Assembly (Fig. 1,

Item 3) to determine if the unit has retained its vacuum seal. 26) If yes, proceed with assembly procedure. If no, remove unit from barrier pouch

and repeat steps 20 thru 25. 27) Apply 2” wide Red Tape (Fig. 3, Item 5) across recent heat sealed end of

Barrier Pouch as shown below.



Page 36

25-64-01 Apr 27/2012

28) Using Notching Tool, cut two (2) notches into Yellow Arrow Labels of Compact Barrier Pouch Assembly (Fig. 1, Item 3) as detailed below.

29) Apply Serial Number Label and Replace By Date Label to the Compact Barrier Pouch Assembly (Fig. 1, Item 3) as detailed below.



Page 37

25-64-01 Apr 27/2012

30) Affix new labels onto Stowage Bracket Sub-Assembly (Fig. 1, Item 2) as detailed below.

31) Apply new labels to the corresponding locations on the PBE TSO & CAA Label

(Fig. 1, Item 7), P/N B-P-4243: Model Number Label (MR10022N); Manufactured By / Serial # Label; Replace by Date Label (use original replace by date); and Date of Manufacture Label (use original manufacture date). Reference Figure 4 on page 7 of this manual.

32) Install Compact Barrier Pouch Assembly (Fig. 1, Item 3) into Stowage Bracket

Sub-Assembly (Fig. 1, Item 2) so as humidity indicator is visible thru clear inspection window.

33) Apply Tamper Seals (Fig. 1, Item 4) onto Stowage Bracket (Fig. 1, Item 2) as

detailed in above drawing.



Page 38

25-64-01 Apr 27/2012

Task 25-64-01-970-801-A E. Documentation Procedures:

1. PBE Hood Traveling Docket, Form # QR-4.10.10035 – The PBE Docket is required to be completed as the assembly procedure is performed. The procedure for preparing the form is detailed below. Also refer to figure 11.

Block # Instruction for Completion

1 Create and Apply Hood Shell Serial Number Bar Code Label

2 Enter NA

3 Enter NA

4 Enter NA

5 Enter NA

6 Enter NA

7 Enter NA

8 Enter NA

9 Enter NA

10 Enter NA

11 Enter Date the Hood Pressure Test was performed.

12 Record the ending pressure in inches of H2O from Pressure Test

13 Enter NA

14 Enter MR10022N

15 If a new End of Service Indicator (EOSI) was used, enter its Receiving Report Number & Lot Number.

16 If a new Front Scrubber Panel was used, enter its Sewing Batch Number.

17 If both Front Scrubber Panels were replaced, enter the second Front Scrubber Panels Sewing Batch Number.

18 If Defogger was applied, enter the date of application and technicians initials or ID number whom performed the task.

19 If a new Top Scrubber Panel was used, enter its Sewing Batch Number.

20 If a new Rear Scrubber Panel was used, enter its Sewing Batch Number.

21 If new Scrubber Panels were installed, enter the date of installation and technicians initials or ID number whom performed the task.

22 Enter the date and technicians initials or ID number who applied the corn starch to the neck seal (anti-blocking).

23 Enter NA

24 Enter the date and technicians initials or ID number who inspected the Hood Shell Assembly.

25 If new Oxygen Assemblies were used, enter their Receiving Report Number.

26 Enter the date and technicians initials or ID number who weighed the Low Flow Oxygen Assembly. Also, enter its weight in grams.



Page 39

25-64-01 Apr 27/2012

27 Enter the date and technicians initials or ID number who weighed the High Flow Oxygen Assembly. Also, enter its weight in grams.

28 Enter the date and technicians initials or ID number who installed the Oxygen Assemblies.

29 Enter the date and technicians initials or ID number who inspected the Hood Shell Assembly.

30 Enter the Receiving Report Number of the Barrier Pouch Subassembly that was used.

31 Enter the date and technicians initials or ID number who folded (packed) the PBE and inserted it into the Barrier Pouch Subassembly.

32 Enter the date and technicians initials or ID number who vacuum packed the PBE in its Barrier Pouch Subassembly.

33 Enter the date and technicians initials or ID number who inspected the Vacuum Packed Barrier Pouch Assembly.

34 Enter the date and technicians initials or ID number who installed the Barrier Pouch Assembly into its Stowage Bracket.

35 Enter the date and technicians initials or ID number who inspected the Stowage Bracket Assembly.

36 If applicable, enter the date and technicians initials or ID number who inspected the unit in its shipping condition.

37 If applicable, enter the date and technicians initials or ID number who shipped the unit.

38 Enter the original Replace by Date of the PBE.

2. Maintenance Repair Data, Form # QR-4.10.10035-1 - The Maintenance Repair Data Form is required to be completed after the assembly procedure is completed. The procedure for preparing the form is detailed below. Also refer to figure 12.

Block # Instruction for Completion

1 Enter Receiving Report Number

2 Enter Customer’s Purchase Order Number

3 Enter Return Material Authorization Number

4 Enter Airline (Customer) the PBE was from

5 Enter Disposition Code of Unit, HR or PR

6 Enter NA

7 Enter any special Comments or Notes

3. Once the repair of the PBE is completed and the PBE Hood Traveling Docket,

Form # QR-4.10.10035 and the Maintenance Repair Data, Form # QR-4.10.10035-1 have been completed – a scanned copy of each document, for each unit that was repaired, shall be e-mailed, faxed or mailed to Essex PB&R Corporation to the attention of Customer Service.



Page 40

25-64-01 Apr 27/2012

4. A Certified Repairman is required to prepare FAA form 8130-3, Airworthiness

Approval Tag for the repaired unit. The 8130-3 Tag is to be completed per FAA Order 8130.21 as revised.



Page 41

25-64-01 Apr 27/2012

Figure 11 – PBE Hood Traveling Docket

33 34

32

35 36 37

16

19 20 21 22

23 24 25 26 27

28 29 30 31

8 9 10

12

11

13 14

18 17 15

38 1

2

5 6 7

3 4



Page 42

25-64-01 Apr 27/2012

Figure 12 – Maintenance Repair Data

7

6

5

4

2

3

1



Page 43

25-64-01 Apr 27/2012

8. SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

A. Refer the table below for a list of tools, fixtures and equipment necessary to do maintenance on the component.



Barcode Printer w/ PC loaded with Barcode Printing Software

Intermec Model PM4i with Loftware – On Demand Print Version Software or equivalent.

1

External E-Ring Pliers For Shaft Diameter of 9/32” (.71 cm) 1

Beaker 100 ml Beaker 1

Leather Punch 5/8” (1.59 cm) diameter Leather Punch 1

Hand Tweezers Commercial Grade 1

Electronic Balance 500 g capacity, .01 g readability 1

Titrator Mettler Model DL50 or equivalent 1

Pressure Test Fixture Specialized Tooling, which can be purchased from Essex PB&R Corporation. (P/N: C-P-8259)

1

Compressed nitrogen or clean, dry compressed air

Used to inflate hoods and supply internal pressure for leak testing.

A/R



1

Heat Gun Varitemp, Model VT-750C or equivalent 1

Hood Shell Jig (Scrubber Installation)

Specialized Tooling, which can be purchased from Essex PB&R Corporation. (P/N: D-P-8258)

1

Small Side Cutters Commercial Grade 1

Notching Tool Specialized Tooling, which can be purchased from Essex PB&R Corporation. (P/N: 45N Punch with Notch Design 28)

1

Vacuum Heat Sealer 1/8” to 3/8” (.32 cm to .95 cm) Heat Seal Width w/ .08 mPA minimum vacuum

1

Barrier Pouch Vacuum Sealing Fixture

Specialized Tooling, which can be purchased from Essex PB&R Corporation. (P/N: B-P-8257)

1



Page 44

25-64-01 Apr 27/2012

9. ILLUSTRATED PARTS LIST

A. General (1) This Illustrated Parts List (IPL) gives illustrations and a breakdown, in

disassembly sequence, of all assemblies that can be disassembled, replaced, and/or reassembled.

B. Explanation and Usage

(1) The “IPL FIG. & ITEM NO.” columns shows the figure and item number for each part. The figure number is shown once in the header row. Each part is identified by an item number. A part that is not illustrated will have a dash (-) before the item number.

(2) The “PART NUMBER” column shows the part number for each part.

(3) The “ AIRLINE PART NO.” column is a blank column with spaces for 11

characters. The airline customer can use this space to record their stock numbers.

(4) The “NOMENCLATURE” column gives the following type of information about

the part:

(a) The indenture level shows how the part is related to the next-higher assembly. For example: 1 2 3 4 5 Assembly * Detail Parts for Assembly

* Subassembly * Attaching parts for Subassembly * * Detail Parts for the Subassembly * * Sub-subassembly * * Attaching Parts for Sub-subassembly * * * Detail Parts for Sub-subassembly

(b) The full name of the part as shown on the drawing title. (c) The true part number if not given in the part number column. (d) Figures are referenced to show that more breakdown information is

available.

(5) The “EFF CODE” column is used to show limited interchangeability only and



Page 45

25-64-01 Apr 27/2012

does not apply to this part number detailed in this CMM. (6) The “UNITS PER ASSY” column gives the quantity of the specified item number

used on one next-higher assembly, subassembly, or sub-subassembly. The letters AR (as required) are for bulk items, and RF indicates that the item is shown for reference only.

(7) Interchangeability Terms, Abbreviations, Definitions, and Related T-File

Explanation Codes (EC).

Term Abbreviation Definition EC

Alternate ALT That part agrees with all functional and structural specifications, but the external dimensions, connection installation, and/or mounting provisions are different. Rework or possible changes can be necessary.

36

Optional OPT The part is fully interchangeable in form, fit, and function with other item numbers shown.

39

Preferred PRFD The part is preferred over the other optional parts shown

71

Replaced By

REPLD The part is replaced and is two-way interchangeable with the item number shown (old part number can replace either old or new part number when removed).

02

Replaces REPLS The part replaces and is two-way interchangeable with the item number shown (new part number is acceptable replacement for old or new part number).

02

Superseded By

SUPSDBY The part is superseded by and is one-way interchangeable with the item number shown (old part number can be used as replacement only where old part was installed).

01

Supersedes

SUPSDS The part is supersedes and is one-way interchangeable with the item number shown (new part number is acceptable replacement for old or new part number).

01

Service Bulletins

SB PRE SB POST SB RWK

Identifies when a service bulletin (SB) has an effect on a part. PRE shows the condition of the part before the work in the service bulletin is done; POST shows the condition after the work is done; RWK shows that the part is reworked by the service bulletin.



Page 46

25-64-01 Apr 27/2012

IPL Figure # 1



Page 47

25-64-01 Aug 19/2013

FIG. & ITEM NO.

PART

NUMBER

AIRLINE

PART NO.

NOMENCLATURE

1 2 3 4 5

EFF

CODE

UNITS PER

ASSY

1 -1 2 3 4 5 6 7 8

MR10022N DP4116 CP3143 BP4231 BP4201 AP4242 BP4243 BPF375

STOWAGE BRACKET ASSEMBLY – COMPLETE (DP4117) * STOWAGE BRACKET SUB-ASSEMBLY * COMPACT BARRIER POUCH ASSEMBLY (REFER TO FIGURE # 2 FOR DETAILS) * TAMPER SEALS * INSTRUCTION LABEL * PULL OPEN LABEL * PBE – TSO & CAA LABEL * BUTTON PLUGS

RF 1 1 2 1 2 1 4

DASH (-) ITEMS NOT ILLUSTRATED.



Page 48

25-64-01 Apr 17/2012

IPL Figure # 2



Page 49

25-64-01 Apr 17/2012

FIG. & ITEM NO.

PART

NUMBER

AIRLINE

PART NO.

NOMENCLATURE 1 2 3 4 5

EFF

CODE

UNITS PER

ASSY

2 -1 2 3 4 5

CP3143 CP2130 AP4119 DP3113A 223RED

COMPACT BARRIER POUCH ASSEMBLY (REFERENCE FIGURE #1 FOR NHA) * COMPACT BARRIER POUCH SUB-ASSY * STIFFENER * HOOD / NECK SEAL ASSEMBLY (REFER TO FIGURE # 3 FOR DETAILS) * RED CLOTH TAPE - 2 INCH WIDE (SUPPLIER – ESSEX PB&R CAGE CODE # 0U058)

RF 1 1 1

AR




Page 50

25-64-01 Apr 17/2012

IPL Figure # 3



Page 51

25-64-01 Apr 17/2012

FIG. & ITEM NO.

PART

NUMBER

AIRLINE

PART NO.

NOMENCLATURE 1 2 3 4 5

EFF

CODE

UNITS PER

ASSY

3 -1 2 3 4 5 6 7 8 9 10 11

DP3113A DP2119 DP2115 CP2116 DP2114 AP3208-8 CS1101 AP1117 98410A112 R3603 CP3209

HOOD / NECK SEAL ASSEMBLY * HOOD SHELL / NECK SEAL SUBASSEMBLY * FRONT SCRUBBER * TOP SCRUBBER * REAR SCRUBBER * OXYGEN DIPENSER ASSEMBLIES * OXYGEN NOZZLE WRAP * PLASTIC WASHER * EXTERNAL RETAINING RING * TYGON TUBING (6” LONG) (ST. GOBAIN CAGE CODE # 61501) * END OF SERVICE INDICATOR

RF 1 2 1 1 1 2 1 1 1 1




Page 52

25-64-01 Apr 17/2012

10. STORAGE

A. Although the packaged PBE in its Stowage Bracket is capable of handling temperature extremes in the range of -20°F to +185°F (-29°C to +85°C) it is recommended that the unit be stored, prior to use, at a temperature range of +32°F to +100°F (0°C to +38°C).

B. Although the packaged PBE in its Stowage Bracket is capable of handling high

humidity levels (100% RH) it is recommended that the unit be stored, prior to use, in clean, relatively dry area with a relative humidity below 75%.

C. The packaged PBE in its Stowage Bracket shall be stored in a secure area,

where it can not be tampered with by unauthorized personnel. D. The packaged PBE in its Stowage Bracket shall not be stored beyond the Shelf-

Life of the unit as indicated by the “Replace by Date” label. The “Replace By Date” label of the unit is located on the front face of the unit and is also visible thru the clear inspection window on the top cover of its Stowage Bracket.

E. Upon removal of the packaged PBE in its Stowage Bracket from storage, the

Testing and Fault Isolation procedure should be performed as detailed on page 14 of this CMM, prior to installation on an aircraft.

Documents

CMM 25-64-01 PBE 22N 8-19-13