CMM - 35-31-55 Rev 8

ZODIAC AEROSPACE SERVICES
TECHNICAL PUBLICATION DEPARTMENT

61, RUE PIERRE CURIE - CS20001
78373 PLAISIR CEDEX - FRANCE
Phone: + 33 (0)1 61 34 23 23 - Fax: +33 (0)1 61 34 21 13
LETTER OF TRANSMITTAL
TO:
USERS REQUIRING A COMPONENT MAINTENANCE MANUAL (CMM) FOR:
AVOX PART NUMBERS: 803668-01, 807434-01, 9700 SERIES, 9800 SERIES
PORTABLE CYLINDER ASSEMBLY
REVISION 08 OF CMM 35-31-55, DATED JUN 21/16 IS ATTACHED
TRANSMITTAL SHEET
Page 1/2
35-31-55 Jun 21/16
The data and information contained herein are proprietary to ZODIAC AEROSPACE SERVICES. Copy and distribution to a third party are strictly forbidden. Printed in France.
ZODIAC AEROSPACE SERVICES
THIS PAGE INTENTIONALLY LEFT BLANK
TRANSMITTAL SHEET
Page 2/2
35-31-55 Jun 21/16
The data and information contained herein are proprietary to ZODIAC AEROSPACE SERVICES. Copy and distribution to a third party are strictly forbidden. Printed in France.
AVOX SYSTEMS INC.
COMPONENT MAINTENANCE MANUAL
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
HIGHLIGHTS
REVISION N°.8 - JUN 21/16
Pages which have been added, revised or deleted are outlined below together with the Highlights of the
revision.
LOCATIONS DESIGNATION DESCRIPTION OF CHANGE

DESCRIPTION AND OPERATION N Updated section to new format.
DESCRIPTION AND OPERATION N Revised dimension data in Table 1 and Table
4.
DESCRIPTION AND OPERATION N Revised Table 2, Table 3 and Figure 6 to add
new PN 807433-02 data.
TESTING AND FAULT ISOLATION N Updated section to new format.
TESTING AND FAULT ISOLATION N Revised paragraph 5.B. and Table 1008 to
show the latest IPL item numbers.
TESTING AND FAULT ISOLATION N Revised to paragraph 7.A. and 7.H to show
new flange hex nut data.
DISASSEMBLY N Updated section to new format.
DISASSEMBLY N Revised paragraphs 2.A.(2), 2.B., 4.B., and
5.A.(5) to show the latest IPL item numbers.
DISASSEMBLY N Revised paragraph 4.E. to show new flange
hex data.
DISASSEMBLY N Revised paragraph 5.C. to show preformed
packing data.
CLEANING N Updated section to new format.
CLEANING N Revised Cleaning section with new format.
CLEANING N Updated Table 4003 to show new reference
document data.
CLEANING N Updated paragraph 2.B. to show new
procedures to clean steel cylinders.
CLEANING N Updated paragraph 5.C. to show new
preformed packing.
INSPECTION/CHECK N Updated section to new format.
INSPECTION/CHECK N Revised paragraph 2.D.(2) to show new
preformed packing data.
INSPECTION/CHECK N Added paragraph 3.
HLTS Page 1
35-31-55 Jun 21/16
The data and information contained herein are proprietary to AVOX SYSTEMS INC.. Copy and distribution to a third party are strictly forbidden. Printed in France.
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
HIGHLIGHTS (Cont’d)
INSPECTION/CHECK N Revised paragraph 4.D and Table 5004 to

show the latest IPL item numbers.
INSPECTION/CHECK N Revised titles of 5.A and 5.B to remove
unnecessary IPL item numbers.
REPAIR N Updated section to new format.
REPAIR N Revised paragraph 3.A.(1), 4.A.(1) and 4.B.(3)
to show the latest IPL item numbers
ASSEMBLY N Updated section to new format.
ASSEMBLY N Updated Table 7002 with new marking ink
data.
ASSEMBLY N Added paragraph 4.A.(4).
ASSEMBLY N Revised torque values in paragraphs 5.A.(5),
5.B.(5), 5.C.(3), 5.D.(5),(8),(9), and 6.C.(2).
ASSEMBLY N Updated paragraph 5.G. with new identification
plate data.
ASSEMBLY N Revised paragraphs 4.A.(4), 6.A thru 6.E.,
6.G. and 8.A. to show the latest IPL item
numbers.
ASSEMBLY N Added Note to paragraph 8.D.(3).
ASSEMBLY N Revised Figure 7008 and Figure 7010 to with
new PN 807434-00 data.
FITS AND CLEARANCES N Updated section to new format.
FITS AND CLEARANCES N Updated Table 8001 with new torque value
data and to show the latest IPL item numbers.
SPECIAL TOOLS, FIXTURES, N Updated section to new format.
EQUIPMENT AND CONSUMABLES
SPECIAL TOOLS, FIXTURES, N Updated Table 9002 with new marking ink
EQUIPMENT AND CONSUMABLES data.
SPECIAL PROCEDURES N Added new procedures.
STORAGE N Revised Table 15002.
HLTS Page 2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
HIGHLIGHTS (Cont’d)
ILLUSTRATED PARTS LIST Updated section to new format.

ILLUSTRATED PARTS LIST Extensively revised to update IPL figures to
ATA format and latest engineering data.
HLTS Page 3
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
HLTS Page 4
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
AIRCRAFT SYSTEMS | CABIN & COCKPIT SYSTEMS DIVISION
(ZODIAC OXYGEN SYSTEMS US)

225 Erie Street
Lancaster NY 14086-95-02 USA
Phone: 716-683-5100
Fax: 716-681-1089
(53655)

WITH ILLUSTRATED PARTS LIST
PORTABLE CYLINDER ASSEMBLY
PART NUMBER
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
803668-01 9700-C1A-B23AN 9700-F1A-BF23AN 9700-G2A-F20AN 9800-1D1A-BF23A 9800-2D1A-F23AN
807434-01 9700-C1A-F20D 9700-F1A-BF23BN 9700-G2A-F20D 9800-1D1A-F23AM 9800-2D1A-F23BM
9700-A1A-BF20B 9700-C1A-F23A 9700-F1A-BY23AN 9700-G2A-F23D 9800-1D1A-F23AN 9800-2D1A-F23A
9700-A1A-BF23A 9700-C1A-F23AM 9700-F1A-YYY0N 9700-G2A-F10D 9800-2C1A-E20A 9800-2D1A-F23BN
9700-A1A-BF23B 9700-C1A-F23AN 9700-F1A-F23AKN 9700-G2A-F23AN 9800-2C1A-E20B 9800-2D1A-F23DM
9700-A1A-B20A 9700-C1A-FF23A 9700-G2A-BF10A 9700-G2X-Y0N 9800-2C1A-E20D 9800-8C1B-F23A
9700-A1A-YY0N 9700-C1A-YY0N 9700-G2A-BF10B 9700-H2A-BF10BN 9800-2C1A-E23A 9800-9C1A-E23A
9700-B1X-BBF25A 9700-C1A-YY0S 9700-G2A-BF10D 9700-H2A-BF20BN 9800-2C1A-E23B 9800-9C1A-F23AM
9700-C1A-BB23A 9700-C1A-Y0N 9700-G2A-BF20A 9700-H2A-BF23BN 9800-2C1A-F23A 9800-9C1A-X0X
9700-C1A-BF20A 9700-C1A-F23BN 9700-G2A-BF20B 9800-1C1A-E20A 9800-2C1A-F23D 9800-9D1A-F23AM
9700-C1A-BF20B 9700-C1B-BF23D 9700-G2A-BF20D 9800-1C1A-E20B 9800-2C1A-X0M

9700-C1A-BF20D 9700-C1C-BF23A 9700-G2A-BF23A 9800-1C1A-E23B 9800-2C1A-X0X
9700-C1A-BF23A 9700-C2C-F20D 9700-G2A-BF23B 9800-1C1A-F20A 9800-2D1A-BF20B
9700-C1A-BF23AM 9700-C3C-BF20D 9700-G2A-BF23D 9800-1C1A-F20B 9800-2D1A-BF23A
9700-C1A-BF23AN 9700-D1A-BBF20B 9700-G2A-BF25A 9800-1C1A-F23A 9800-2D1A-E23AM
9700-C1A-BF23B 9700-D1A-BBF23A 9700-G2A-FF25B 9800-1C1A-X0N 9800-2D1A-F20BM
9700-C1A-BF23D 9700-F1A-BF23AM 9700-G2A-F10AN 9800-1C1A-X0X 9800-2D1A-F23AM
REVISION No.:8 TP Page 1

ORIGINAL ISSUE: Feb 01/70 35-31-55 Jun 21/16
Copyright © 2016 by ZODIAC AEROSPACE. All rights reserved.
The data and information contained in this document are proprietary rights of ZODIAC
AEROSPACE. This document is given in confidence and may not be reproduced, stored in a
retrieval system, or transmitted to a third party, in any form or by any means, electronic, mechanical,
photocopying, or otherwise, without the prior written permission of ZODIAC AEROSPACE.
Any unauthorized copy, distribution or utilization is illegal according to Article L 122-4 and L 335-2
of the "Code de la Propriété Intellectuelle" ("Code of the Intellectual Property") and to international
agreements related to proprietary rights.
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
RECORD OF REVISIONS
REV INSERTED REV INSERTED
ISSUE DATE ISSUE DATE
No DATE BY No DATE BY
Original FEB 01/70 FEB 01/70 AVOX
1 SEP 30/75 SEP 30/75 AVOX
2 FEB 20/81 FEB 20/81 AVOX
3 MAR 01/83 MAR 01/83 AVOX
4 DEC 20/85 DEC 20/85 AVOX
5 DEC 31/99 DEC 31/99 AVOX
6 MAR 31/04 MAR 31/04 AVOX
7 FEB 27/12 FEB 27/12 AVOX
8 JUN 21/16 JUN 21/16 ZSU
ROR Page 1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
ROR Page 2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
RECORD OF TEMPORARY REVISIONS
TEMP INSERTED REMOVED

ISSUE DATE PAGE NO.
REV NO.
DATE BY DATE BY
RTR Page 1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
RTR Page 2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SERVICE BULLETIN LIST

REV ISSUE INCORP.
SB/SIL No. TITLE
No. DATE DATE
SIL-35-23 0 Feb 14/03 Mar 31/04
SIL-35-25 0 Feb 14/03 Mar 31/04
SIL-35-51 1 Feb 14/03 Feb 27/12
SIL-35-54 2 Jun 01/06 Feb 27/12
SIL-35-106 0 Jul 10/07 Feb 27/12
SIL-35-117 1 Apr 06/10 Feb 27/12
SIL-35-67 0 Nov 20/08 Feb 27/12
SIL-35-122 0 May 11/09 Feb 27/12
SIL-35-103 4 Oct 09/09 Feb 27/12
SIL-35-125 2 Feb 22/10 Feb 27/12
SIL-35-127 0 Apr 06/10 Feb 27/12
SIL-35-130 0 Jun 15/10 Feb 27/12
SIL-35-131 0 Jun 15/10 Feb 27/12
SIL-35-126 2 Dec 05/11 Feb 27/12
SIL-35-132 3 Dec 05/11 Feb 27/12
SIL-35-106 1 Feb 24/12 Feb 27/12
SIL-35-127 1 Apr 30/12 Jun 21/16
SIL-35-149 1 Aug 07/13 Jun 21/16
9700-35-01 0 May 04/12 Jun 21/16
9800-35-01 0 May 04/12 Jun 21/16
6084-00-35-01 0 May 03/16 Jun 21/16
SBL Page 1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SBL Page 2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

TITLE PAGE 1 Jun 21/16 7 Jun 21/16
2 Jun 21/16 8 Jun 21/16
RECORD OF REVISIONS RR-1 Jun 21/16 9 Jun 21/16
RR-2 Blank 10 Jun 21/16
RECORD OF TEMPORARY 1 Jun 21/16 11 Jun 21/16
REVISIONS 2 Blank 12 Jun 21/16
SERVICE BULLETIN LIST 1 Jun 21/16 13 Jun 21/16
2 Blank 14 Jun 21/16
LIST OF EFFECTIVE PAGES 1 Jun 21/16 15 Jun 21/16
2 Jun 21/16 16 Jun 21/16
3 Jun 21/16 17 Jun 21/16
4 Jun 21/16 18 Jun 21/16
5 Jun 21/16 19 Jun 21/16
TABLE OF CONTENTS 1 Jun 21/16 21 Jun 21/16
2 Jun 21/16 22 Jun 21/16
3 Jun 21/16 23 Jun 21/16
4 Jun 21/16 24 Jun 21/16
5 Jun 21/16 25 Jun 21/16
6 Jun 21/16 26 Jun 21/16
7 Jun 21/16 27 Jun 21/16
TABLE OF FIGURES 1 Jun 21/16 29 Jun 21/16
2 Jun 21/16 30 Blank
3 Jun 21/16 TESTING AND FAULT 1001 Jun 21/16
4 Blank ISOLATION 1002 Jun 21/16
INTRODUCTION INTRO 1 Jun 21/16 1003 Jun 21/16
INTRO 2 Jun 21/16 1004 Jun 21/16
INTRO 3 Jun 21/16 1005 Jun 21/16
INTRO 4 Jun 21/16 1006 Blank
INTRO 5 Jun 21/16 1007 Jun 21/16
INTRO 6 Jun 21/16 1008 Blank
DESCRIPTION AND 1 Jun 21/16 1009 Jun 21/16
OPERATION 2 Jun 21/16 1010 Jun 21/16
3 Jun 21/16 1011 Jun 21/16
4 Jun 21/16 1012 Jun 21/16
5 Jun 21/16 1013 Jun 21/16
6 Jun 21/16 1014 Jun 21/16
LEP Page 1
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
LIST OF EFFECTIVE PAGES (Cont'd)
1015 Jun 21/16 4003 Jun 21/16

1016 Jun 21/16 4004 Blank
1017 Jun 21/16 4005 Jun 21/16
1018 Blank 4006 Blank
1019 Jun 21/16 4007 Jun 21/16
1020 Jun 21/16 4008 Blank
1021 Jun 21/16 4009 Jun 21/16
1023 Jun 21/16 4011 Jun 21/16
1025 Jun 21/16 4013 Jun 21/16
1026 Jun 21/16 4014 Blank
1027 Jun 21/16 4015 Jun 21/16
1028 Jun 21/16 4016 Blank
1029 Jun 21/16 INSPECTION/CHECK 5001 Jun 21/16
1030 Jun 21/16 5002 Jun 21/16
1031 Jun 21/16 5003 Jun 21/16
1032 Jun 21/16 5004 Jun 21/16
1033 Jun 21/16 5005 Jun 21/16
1034 Jun 21/16 5006 Blank
DISASSEMBLY 3001 Jun 21/16 5007 Jun 21/16
3002 Jun 21/16 5008 Jun 21/16
3003 Jun 21/16 5009 Jun 21/16
3004 Jun 21/16 5010 Jun 21/16
3005 Jun 21/16 5011 Jun 21/16
3006 Jun 21/16 5012 Jun 21/16
3007 Jun 21/16 5013 Jun 21/16
3008 Jun 21/16 5014 Blank
3009 Jun 21/16 5015 Jun 21/16
3010 Jun 21/16 5016 Blank
3011 Jun 21/16 REPAIR 6001 Jun 21/16
3012 Jun 21/16 6002 Jun 21/16
3013 Jun 21/16 6003 Jun 21/16
3015 Jun 21/16 6005 Jun 21/16
CLEANING 4001 Jun 21/16 6007 Jun 21/16
4002 Jun 21/16 6008 Jun 21/16
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
6009 Jun 21/16 7034 Jun 21/16

6010 Jun 21/16 7035 Jun 21/16
6011 Jun 21/16 7036 Jun 21/16
6012 Blank 7037 Jun 21/16
7038 Jun 21/16
ASSEMBLY 7001 Jun 21/16
7039 Jun 21/16
7002 Jun 21/16
7040 Jun 21/16
7003 Jun 21/16
7041 Jun 21/16
7004 Jun 21/16
7042 Jun 21/16
7005 Jun 21/16
7043 Jun 21/16
7006 Blank
7044 Jun 21/16
7007 Jun 21/16
7045 Jun 21/16
7008 Blank
7046 Blank
7009 Jun 21/16
7047 Jun 21/16
7010 Jun 21/16
7048 Blank
7011 Jun 21/16
FITS AND CLEARANCES 8001 Jun 21/16
7012 Jun 21/16
8002 Jun 21/16
7013 Jun 21/16
7014 Blank SPECIAL TOOLS, 9001 Jun 21/16
7015 Jun 21/16 FIXTURES, EQUIPMENT 9002 Jun 21/16
7016 Jun 21/16 AND CONSUMABLES 9003 Jun 21/16
7017 Jun 21/16 9004 Jun 21/16
7018 Jun 21/16 9005 Jun 21/16
7019 Jun 21/16 9006 Jun 21/16
7020 Jun 21/16 SPECIAL PROCEDURES 11001 Jun 21/16

7021 Jun 21/16 11002 Jun 21/16
7022 Jun 21/16 11003 Jun 21/16
7023 Jun 21/16 11004 Jun 21/16
7024 Jun 21/16 11005 Jun 21/16
7025 Jun 21/16 11006 Blank
7026 Jun 21/16 STORAGE 15001 Jun 21/16
7027 Jun 21/16 15002 Jun 21/16
7028 Jun 21/16 15003 Jun 21/16
7029 Jun 21/16 15004 Blank
7030 Jun 21/16 15005 Jun 21/16
7031 Jun 21/16 15006 Jun 21/16
7032 Jun 21/16 15007 Jun 21/16
7033 Jun 21/16 15008 Jun 21/16
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AVOX SYSTEMS INC.
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15009 Jun 21/16 10001-4 Jun 21/16
15010 Blank 10001-5 Jun 21/16
REWORK 16001 Jun 21/16 10001-6 Jun 21/16
16002 Jun 21/16 10001-7 Jun 21/16
16003 Jun 21/16 10001A-0 Jun 21/16
16004 Jun 21/16 10001A-1 Jun 21/16
16005 Jun 21/16 10001A-2 Jun 21/16
16006 Blank 10001A-3 Jun 21/16
10001B-0 Jun 21/16
ILLUSTRATED PARTS LIST 1 Jun 21/16
10001B-1 Jun 21/16
IPL 10001 2 Blank
10001B-2 Jun 21/16
INTRO 10001 1 Jun 21/16
10001B-3 Jun 21/16
2 Jun 21/16
10001B-4 Jun 21/16
3 Jun 21/16
10001B-5 Jun 21/16
4 Jun 21/16
10001C-0 Jun 21/16
5 Jun 21/16
10001C-1 Jun 21/16
6 Jun 21/16
10002-0 Jun 21/16
VCI 10001 1 Jun 21/16
10002-1 Jun 21/16
2 Blank
10002-2 Jun 21/16
NI/ALPHA 10001 1 Jun 21/16 10002-3 Jun 21/16
2 Jun 21/16 10003-0 Jun 21/16
3 Jun 21/16 10003-1 Jun 21/16
4 Jun 21/16 10003-2 Jun 21/16
5 Jun 21/16 10003-3 Blank
6 Jun 21/16 10004-0 Jun 21/16
7 Jun 21/16 10004-1 Jun 21/16
8 Jun 21/16 10004-2 Jun 21/16
9 Jun 21/16 10004-3 Jun 21/16
10 Jun 21/16 10005-0 Jun 21/16
11 Jun 21/16 10005-1 Jun 21/16
12 Jun 21/16 10005-2 Jun 21/16
13 Jun 21/16 10005-3 Blank
14 Jun 21/16 10006-0 Jun 21/16
DPL 10001 1 Jun 21/16 10006-1 Jun 21/16
10001-0 Jun 21/16 10007-0 Jun 21/16
10001-1 Jun 21/16 10007-1 Jun 21/16
10001-2 Jun 21/16 10007-2 Jun 21/16
10001-3 Jun 21/16 10007-3 Jun 21/16
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10007-4 Jun 21/16

10007-5 Jun 21/16
10008-0 Jun 21/16
10008-1 Jun 21/16
10009-0 Jun 21/16
10009-1 Jun 21/16
10010-0 Jun 21/16
10010-1 Jun 21/16
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 1
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 1
A. Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 1
B. How to Use the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 2
C. Process Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 2
D. Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 2
E. Manual Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 3
F. Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 4
G. Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 4
H. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 6
I. Product Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO 6
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1. PORTABLE CYLINDER ASSEMBLY - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Optional PCA Mounting Bracket Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Technical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. Part Number Identification for PN 9700 Series and PN 9800 Series PCAs . . . . . 16
F. Part Number Guidelines for PN 9700 Series and PN 9800 Series PCAs . . . . . . . 17
2. PORTABLE CYLINDER ASSEMBLY - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A. Harness Assemblies and Mask Assemblies Stored in Fastener-Mounted Storage
Bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B. Respirator Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
C. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
D. Regulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
E. Regulator Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F. Overhaul Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TESTING AND FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

1. PORTABLE CYLINDER ASSEMBLY - TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
B. Job Set-Up Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
C. Test Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005
2. Relief Valve Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007
A. Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007
B. Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007
C. Pressure to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007
3. Outlet Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1009
TOC Page 1
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TABLE OF CONTENTS (Cont'd)

A. Full Flow (non-metered) Outlet Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1009
B. Leak Test of Test Setup for Constant Flow (Metered) Outlet Assemblies . . . . . . . 1010
C. “Precision” Type Constant Flow (metered) Outlet Assemblies . . . . . . . . . . . . . . . . . . 1010
D. “Adjustable” Type Constant Flow (Metered) Outlet Assemblies . . . . . . . . . . . . . . . . 1011
4. Respirator Regulator Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013
A. Demand Valve Assembly Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013
B. Inward Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014
C. Outward Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014
D. Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1015
5. Regulator Assembly Outlet Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1019
A. Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1019
6. Gauge Accuracy Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1021
A. Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1021
7. On-Off Valve Kit Torque Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1023
A. Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1023
8. PCA Final Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1025
A. External leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1025
B. Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1026
9. Fault Isolation and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1027
A. Fault Isolation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1027
SCHEMATICS AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOT APPLICABLE
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
1. PORTABLE CYLINDER ASSEMBLY - DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
2. General PCA Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3003
A. 9800 Series Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3003
B. 807434, 9700, & 9800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3004
C. 9700 Series Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3005
D. 803668-01 PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3006
3. Respirator Regulator Assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3007
A. Cover Assembly Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3007
B. Diaphragm Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3007
C. Deflector and Demand Valve Assembly Removal and Disassembly . . . . . . . . . . . . 3007
D. General Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3008
4. Regulator Port Device Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3009
A. Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3009
B. Relief Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3009
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES

C. Charging Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3009
D. Safety Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3010
E. On-Off Valve Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3010
F. APN 5009-00, 5009 Series Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011
G. APN 5041-00, 5041 Series Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011
H. APN 5507-00, 5507 Series Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3012
I. APN 10003566 Oxygen Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3012
J. APN 802856-01 Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3012
K. APN 5052-00 Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3013
L. APN DPB153 Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3013
M. APN 36728-01 Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3013
N. APN 10008298 Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3013
5. General Regulator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3015
A. 807434, 9700, and 9800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3015
B. 9700-G2A and 9700-H2A Series Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3015
C. P/N 807434 Series Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3015
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
1. PORTABLE CYLINDER ASSEMBLY - CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
A. Job Set-Up Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
2. Cleaning of the Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005
A. External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005
B. Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005
3. Passenger Mask Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4007
4. Metallic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4009
A. Cleaning Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4009
5. Non-Metallic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4011
A. Cleaning Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4011
6. Miscellaneous Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4013
7. Optional Cylinder Mounting Bracket Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4015
INSPECTION/CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
1. PORTABLE CYLINDER ASSEMBLY - INSPECTION/CHECK . . . . . . . . . . . . . . . . . . . . . . . 5001
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
2. Overhaul (Incorporation of SIL-35-23, SIL-35-25, and SIL-35-117) . . . . . . . . . . . . . . . . . . 5003
A. Overhaul Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003
B. Minimum Necessary Parts to Replace for an Overhaul . . . . . . . . . . . . . . . . . . . . . . . . 5003
C. Functional Tests that are Necessary After an Overhaul . . . . . . . . . . . . . . . . . . . . . . . 5003
D. Overhaul of a PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5004
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES

E. Items to be replaced with new parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005
3. Service Flow Check (Incorporation of SB 9700-35-01 and SB 9800-35-01) . . . . . . . . . . 5007
A. Affected PCAs with Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5007
4. PCA and PCA Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5009
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5009
B. Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5009
C. Plates, Decals, Placards and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5009
D. Harness Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5009
E. Harness Assemblies with Passenger Mask and Storage Bag . . . . . . . . . . . . . . . . . . 5010
5. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5011
A. DOT-SP-8162-1850 Composite Cylinder and DOT-SP-10915-1850 Composite
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5012
B. DOT-3AA-1800 Steel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5013
6. Optional PCA Mounting Bracket Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5015
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
1. PORTABLE CYLINDER ASSEMBLY – REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
2. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
A. to clean the unit, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
B. Removal of sharp edges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
C. Thread repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
D. Replacement of cracked, bent, broken, scratched, or otherwise damaged
components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
E. Steel cylinder paint application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
F. Composite cylinder paint application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
G. Repair of optional PCA mounting bracket assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 6005
3. Steel Cylinder Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6007
A. Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6007
B. Primer Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6007
C. Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6008
4. Composite Cylinder Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6009
A. Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6009
B. Paint Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6010
5. Optional PCA Mounting Bracket Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011
A. For repair information for optional Mounting Bracket Assemblies APN 36758-11,
-12, -22, refer to AVOX Systems ACMM 35-37-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES

1. PORTABLE CYLINDER ASSEMBLY - ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
2. Pre-Assembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7007
A. and as required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7007
B. Unless noted otherwise, all preformed packings shall be lubricated with a thin
film of Fuel and Oxidizer Resistant Aircraft and Instrument Grease prior to
installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7007
C. Unless noted otherwise, all parts which require threading, twisting or turning
operations for assembly will be threaded, twisted or turned in a clockwise
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7007
D. When indicated, apply Thread Sealing Tape according to Commercial Item
Description Specification A-A-58092 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7007
E. When indicated, apply Lockwire according to National Aeronautical Standard
MS33540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7007
F. When indicated, apply Primer and Adhesive in small amounts and wipe off
excess with a clean cloth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7007
G. A “text arrow”, when used, shows the correct alignment of labels, decals and
placards put on the 807434, 9700, and 9800 Series PCA. . . . . . . . . . . . . . . . . . . . . 7007
3. Outlet Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7009
A. Constant Flow (Metered) Type Outlet Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7009
B. 5009-00, 5009 Series constant flow (metered) outlet assemblies . . . . . . . . . . . . . . 7009
C. 5041-00, 5041 Series constant flow (metered) outlet assemblies . . . . . . . . . . . . . . 7010
D. 5507-00, 5507 Series constant flow outlet assemblies . . . . . . . . . . . . . . . . . . . . . . . . 7011
E. 5052-00 constant flow outlet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7011
F. Full Flow (Non-metered) Type Outlet Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7012
4. Respirator Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7015
A. General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7015
B. Demand Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7015
C. Demand Valve Assembly Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7015
D. Deflector (18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7016
E. Diaphragm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7016
F. Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7017
5. Regulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7021
A. General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7021
B. Safety Outlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7021
C. Charging Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7022
D. On-Off Valve Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7022
E. Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7023
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F. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7024
G. Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7024
6. PCA Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7025
A. Regulator Assembly installed into steel cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7025
B. Regulator Assembly installed into composite cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 7025
C. Relief Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7026
D. Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7026
E. Respirator Regulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7027
F. Outlet Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7028
G. ID decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7032
7. PCA Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7035
A. PCA Charging Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7035
B. Charge the PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7035
C. Disconnect the PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7036
D. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7036
8. Final PCA Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7037
A. P/N 801660-00 Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7037
B. P/N 801658-00 Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7038
C. P/N 805118-01 Harness Assembly with Mask and Storage Bag . . . . . . . . . . . . . . 7039
D. P/N 803177-01 Harness Assembly with Mask and Storage Bag . . . . . . . . . . . . . . 7042
9. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7045
10. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7047
FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001

1. PORTABLE CYLINDER ASSEMBLY - FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . 8001
A. Table of Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES . . . . . . . . . . . . . . . . . . . . . 9001

1. PORTABLE CYLINDER ASSEMBLY - SPECIAL TOOLS, FIXTURES, EQUIPMENT
AND CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
A. List of Special Tools, Fixtures and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
B. List of Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005
SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11001

1. PORTABLE CYLINDER ASSEMBLY - SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . 11001
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11001
C. Procedure for measuring residual pressure in oxygen cylinder and regulator
assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11002
D. Evacuation and Recharging Procedures for the 9700 and 9800 Series PCAs . . . 11004
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REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOT APPLICABLE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOT APPLICABLE
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOT APPLICABLE
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001
1. PORTABLE CYLINDER ASSEMBLY - STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001
A. Job Set-Up Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001
2. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15003
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15003
3. Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15005
A. Final Rule [(49 CFR 173.302a(f)(2)(i) and (ii))] (SIL-35-103) . . . . . . . . . . . . . . . . . . . 15005
B. New US DOT HM224B Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15006
REWORK .............................................................................. 16001

1. New US FAA Rule (RIN 2120-AF77) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16001
A. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16001
B. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16001
C. Accomplishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16003
D. To Order Replacement Instruction Labels Free of Charge: . . . . . . . . . . . . . . . . . . . . 16004
E. To Buy a Mask Storage Bag or Velstrap®: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16004
ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IPL 10001 1

INTRODUCTION TO THE ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . INTRO 10001 1
VENDOR'S CODE INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VCI 10001 1
ALPHA NUMERICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NI/ALPHA 10001 1
DETAILED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPL 10001 1
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TABLE OF FIGURES
FIGURE PAGE
DESCRIPTION AND OPERATION

1 807434, 9700, AND 9800 SERIES PORTABLE CYLINDER ASSEMBLY (9800
SERIES PCA PICTURED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 807434 AND 9700 SERIES PCA LEADING PARTICULARS (ENVELOPE
DIMENSIONS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 9800 SERIES PCA LEADING PARTICULARS (ENVELOPE DIMENSIONS) . . . . . . . . . 8
4 9700 SERIES PCA MATRIX (SHEET 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 RESPIRATOR REGULATOR ASSEMBLY (DEMAND TYPE SHOWN) . . . . . . . . . . . . . . . 20
6 REGULATOR ASSEMBLY PN’S 801160-00 THRU -04; 803199-04, -05; AND
807433-02 (CROSS SECTIONAL VIEW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7 CHARGING VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 RELIEF VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9 5009, 5041 AND 5507 SERIES PRECISION OUTLET ASSEMBLY MARKINGS . . . . . 27
10 OUTLET ASSEMBLY AND MATING CONNECTOR COMBINATIONS . . . . . . . . . . . . . . . 28
TESTING AND FAULT ISOLATION

1001 RELIEF VALVE ASSEMBLY TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007
1002 OUTLET ASSEMBLY TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010
1003 DEMAND VALVE ASSEMBLY LEAKAGE TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013
1004 INWARD/OUTWARD LEAKAGE TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014
1005 FLOW TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1015
1006 OUTPUT PRESSURE TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020
1007 GAUGE ACCURACY TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1021
1008 ON-OFF VALVE KIT TORQUE TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1023
1009 TEST DATA SHEET (SHEET 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1032
INSPECTION/CHECK
5001 RE-IDENTIFICATION OF THE PCA (EXAMPLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5008
ASSEMBLY
7001 COVER ASSEMBLY IDENTIFICATION PLATE PLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 7019
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TABLE OF FIGURES (Cont'd)
FIGURE PAGE
7002 SLIDE BUTTON AND SPRING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7019

7003 PLATE W/ LEVER ASSEMBLY AND COMPRESSION SPRING INSTALLATION . . . . . 7020
7004 ON-OFF VALVE KIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7023
7005 807434 AND 9700 SERIES PCA OUTLET ASSEMBLY POSITION AND
MARKINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7029
7006 9800 SERIES PCA OUTLET ASSEMBLY POSITION AND MARKINGS . . . . . . . . . . . . . 7030
7007 9800 SERIES PCA OUTLET ASSEMBLY POSITION AND MARKINGS . . . . . . . . . . . . . 7030
7008 807434 AND 9700 SERIES PCA LABELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7031
7009 9800 SERIES PCA AND 803668-01 PCA LABELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7032
7010 PN 801660-00 HARNESS CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7038
7011 PN 801658 HARNESS CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7039
7012 PN’S 805118-01, MASK STORAGE BAG AND HARNESS ASSEMBLY . . . . . . . . . . . . . 7041
7013 MASK STORAGE BAG ASSEMBLY CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7044
STORAGE
15001 CYLINDER SHIPPING TAG PN 10015660 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15008
REWORK
16001 REPLACEMENT INSTRUCTION LABELS PN 10009072 03/06 AND PN 10009071
03/06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16002
16002 PLACEMENT OF LABEL ON CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16004
DETAILED PARTS LIST

1 9700-A, 9700-B, 9700-C, 9700-D, AND 9700-F SERIES PCA (SHEET 1) . . . . . . 10001-0
9700-A, 9700-B, 9700-C, 9700-D, AND 9700-F SERIES PCA (SHEET 2) . . . . . . 10001-1
1A 9700-G2A AND 9700-H2A SERIES PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001A-0
1B 9800 SERIES PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001B-0
1C 807434 SERIES PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001C-0
2 801242-01, -02, -03, AND -04 RESPIRATOR REGULATOR ASSEMBLY . . . . . . . 10002-0
3 5009-00, 5009 SERIES OUTLET ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10003-0
4 5041-00, 5041 SERIES OUTLET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10004-0
5 5507-00, 5507 SERIES OUTLET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10005-0
6 DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10006-0
7 80116-00 THRU -04, 803199-04, -05, AND 807433-02 REGULATOR
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10007-0
8 802856-01 OUTLET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10008-0
9 2661-03, 2661-04, 802821-01PRESSURE GAUGE ASSEMBLY . . . . . . . . . . . . . . . 10009-0
TOF Page 2
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TABLE OF FIGURES (Cont'd)
FIGURE PAGE
10 PORTABLE CYLINDER ASSEMBLY 803668-01 OPTIONAL NEXT HIGHER

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10010-0
TOF Page 3
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TOF Page 4
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
INTRODUCTION
TASK 35-31-55-990-801-A01
1. Introduction
A. Information
(1) The CMM is written in accordance with the Air Transport Association (ATA) of
America Specification No. 2200, Revision 2000-1 and in Association Europeene
des Constructeurs de Materiel Aerospatial (AECMA) Simplified English.
(2) The CMM gives all the procedures supplied by the manufacturer for use in the
workshop, so that all persons can repair and completely overhaul the component.
(3) The manual describes maintenance on the component in a workshop. It does
not define or show the level of maintenance for all special units, but gives all the
procedures necessary to let the person to do a test, disassemble, clean, check and
assemble a unit which has been rejected from serviceable use. The manual does
not describe maintenance on the component when it is installed on the aircraft.
(4) Only approved persons are permitted to do the maintenance procedures given in
this manual.
(5) Maintenance Task Oriented Support System (MTOSS) task and subtask
identification is used in this manual. The maintenance tasks and other data have
special MTOSS numbers for use of Electronic Data Processing (EDP). The user
of manual can ignore the MTOSS numbers.
(6) Where the data or procedures specified in this manual are different from those
specified by the regulatory agency which controls operation of your aircraft, obey
the data and procedures of the regulatory authority.
(7) This manual contains:
– Technical data for the component,
– Maintenance and repair procedures for the component,
– An Illustrated Parts List (IPL) or Illustrated Parts Catalog (IPC) with data for
the component parts. The IPL Figure and item number identifies parts in
all sections of the manual.
INTRO Page 1
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
B. How to Use the Manual

(1) Make sure the manual contains the information applicable to your component.
Look on the Title Page for the part number.
(2) If it is necessary to identify a part or find a part number, refer to the IPL (or IPC),
which has an introduction to show the procedure.
(3) The instructions in this manual must be used for all component maintenance.
Read all the applicable WARNINGS and CAUTIONS before you do the work
on the component.
C. Process Verification
(1) The manufacturer has validated the "Disassembly, Testing and Fault Isolation and
Assembly" procedures in this manual.
(2) For 9700-A Series, 9700-B Series, 9700-C Series, 9700-D Series, 9700-F Series
– Disassembly: verified by performance : OCT 14/82
– Testing and Fault Isolation: verified by performance : OCT 14/82
– Assembly: verified by performance : OCT 14/82
(3) For 9700-G2A Series, 9700-H2A Series
– Disassembly: verified by performance : DEC 9/95
– Testing and Fault Isolation: verified by performance : NOV 14/95
– Assembly: verified by performance : NOV 14/95
D. Modification
(1) All result data and illustrations in this manual are the last revision available at the
time of printing. AVOX supplies updates to this manual when necessary. When
AVOX issues a modification to units included in this manual, AVOX will revise
the manual to include the information.
(2) When there is a change, each updating gives the full instructions about the page
number of the pages, which must be replaced, added or removed. Revised test or
new texts are located with a vertical black line in the left margin.
INTRO Page 2
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
E. Manual Guidelines
(1) The CMM is divided into page blocks:
PAGE BLOCK TITLE

0001-0999 DESCRIPTION AND OPERATION
1001-1999 TESTING AND FAULT ISOLATION
2001-2999 SCHEMATICS AND WIRING DIAGRAMS
3001-3999 DISASSEMBLY
4001-4999 CLEANING
5001-5999 INSPECTION/CHECK
6001-6999 REPAIR
7001-7999 ASSEMBLY
8001-8999 FITS AND CLEARANCES
9001-9999 SPECIAL TOOLS, FIXTURES, EQUIPMENT AND
CONSUMABLES
10001-10999 ILLUSTRATED PARTS LIST
11001-11999 SPECIAL PROCEDURES
12001-12999 REMOVAL
13001-13999 INSTALLATION
14001-14999 SERVICING
15001-15999 STORAGE
16001-16999 REWORK
INTRO Page 3
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
F. Measurements
(1) The measurements given in this manual are taken from the original reference
document of the manufacturer.
(2) All values given in this manual are in Imperial units or United States (U.S.) units or
sub-divisions of these units. System International (SI) or metric units are given in
parenthesis immediately after the Imperial units. The decimal point in the Imperial
system is shown in the SI as a comma, e.g. 1.00 in. (25,4 mm).
(3) Measurement conversion table:
From : SI measurement To : U.S. standard system

1 kPa 0.1450 psi
1 cm 0.3937 in.
1 N 0.2248 lbf
1 g 0.0353 oz
1 kg 2.2046 lb
1 L 0.2642 gal (U.S.)
1 L/min 0.2642 gal/min (U.S.)
1 mm 0.0394 in.
1 N.m 8.8507 lbf-in.
1 N.m 0.7376 lbf-ft
From : U.S. standard system To : SI measurement
1 psi 6,8948 kPa
1 in. 25,4 mm
1 lbf 4,4482 N
1 oz 28,3495 g
1 in.Hg 3,3864 kPa
1 lb 0,4536 kg
1 gal (U.S.) 3,7854 L
1 lbf-in. 0,1130 N.m
1 lbf-ft 1,3558 N.m
G. Abbreviations and Acronyms

(1) The abbreviations and acronyms used in this manual are given below:
– °C = degree Celsius
– °F = degree Fahrenheit
– cm = centimeter
– ccm = cubic centimeter per minute
– ft³ = cubic foot
– gal = gallon
INTRO Page 4
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
– in. = inch
– in.³ = cubic inch
– in. Hg = Mercury inch
– kg = kilogram
– l = liter
– lb = pound
– lbf-ft = foot-pound
– lbf-in. = inch-pound
– lph = liter per hour
– lpm = liter per minute
– m = meter
– mm = millimeter
– mm.Hg = Mercury millimeter
– MPa = MegaPascal
– N.m = Newton-meter
– oz = ounce
– psi = pound per square inch
– psig = pound per square inch gage
– QTY = quantity
– U.S. = United States
– AECMA = Association Europeene des Constructeurs de Materiel Aerospatial
– ATA = Air Transport Association
– CMM = component maintenance manual
– CSN = catalog sequence number
– DOT = Department of Transportation
– DPL = detailed parts list
– EDI = equipment designator index
– EDP = electronic data processing
– FAR = federal aviation regulation
– IPC = illustrated parts catalog
– IPL = illustrated parts list
– MTOSS = maintenance task oriented support system
– NI = numerical index
– NTPD = normal temperature and pressure dry
– PN or PNR = part number
– SI = system international
– SN= serial number
– STPD = standard temperature and pressure dry
– TC = Transport Canada
– VCI = vendor code index
INTRO Page 5
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
H. Revision
(1) When there is a change, each updating shows the detailed instructions about the
page number of the pages which must be replaced, added or removed.
I. Product Support Services

(1) For technical documentation:
Civilian Operators: Military Operators:

ZODIAC AEROSPACE SERVICES EUROPE AVOX Systems Inc.
Technical Publications Department Technical Publications Department
61 rue Pierre Curie 225 Erie Street
CS20001 Lancaster, NY 14086-9502 USA
78373 Plaisir cedex Phone: 1 716 683 5100
France Fax: 1 716 681 1089
Email: zs.tac@zodiacaerospace.com Email: TechPub.Avox@zodiacaerospace.com
(2) For technical support:
ZODIAC AEROSPACE SERVICES AMERICAS

Bill McGowan
Product Support Specialist
1740 Highway 34 N
Wall, NJ 07719
USA
Email: zs.tac@zodiacaerospace.com
Phone : +33 970 830 830
(3) For repair, overhaul, replacement parts and AOG:
ZODIAC AEROSPACE SERVICES ZODIAC AEROSPACE ZODIAC AEROSPACE SERVICES

EUROPE SERVICES UK MIDDLE EAST
61, RUE PIERRE CURIE - CS 20001 Unit 610, Avenue West Dubai World Central Aviation City -
78373 PLAISIR CEDEX / FRANCE Skyline 120 Logistic City
Phone : +33 970 830 830 CM77 7AA Braintree / UK PLOT NO: DLC-CL-1-WB14 & WB15
Fax : +33 1 64 86 69 79 Phone : +33 970 830 830 PO 644324 DUBAI
www.services.zodiacaerospace.com Fax : 44 (0)-1376-340-734 UNITED ARAB EMIRATES
Phone : +33 970 830 830
ZODIAC AEROSPACE SERVICES ZODIAC AEROSPACE SERVICES
AMERICAS ASIA
6734 Valjean Avenue 36, Loyang Drive
VAN NUYS, CA 91406 SINGAPORE 508949
USA Phone : +33 970 830 830
Phone : +33 970 830 830 Fax : + 65 6579 2231
Fax: +1 818 994 7901
INTRO Page 6
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
DESCRIPTION AND OPERATION
TASK 35-31-55-870-801-A01
1. PORTABLE CYLINDER ASSEMBLY - GENERAL
SUBTASK 35-31-55-870-001-A01
A. Purpose
This section describes the components and operation of the 807434 Series, 9700
Series, and 9800 Series Portable Cylinder Assemblies (PCA). Information about part
numbers, and how to order Portable Cylinder Assemblies is also presented in this
section. (Refer to Fig. 1) for an illustration of a typical PCA.
The 807434 Series and 9700 Series PCAs are portable oxygen sources that contain
high-pressure aviation grade oxygen (per Military Specification MIL-PRF-27210, Type I
or SAE AS8010, Type I) for high altitude breathing or therapeutic use.
The 9800 Series PCA is a dual purpose portable oxygen source that contains
high-pressure aviation grade oxygen (per Military Specification MIL-PRF-27210, Type I
or SAE AS8010, Type I) for high altitude breathing or therapeutic use. In addition to
providing a constant flow of supplemental oxygen, like the 9700 Series PCA, the 9800
Series PCA also provides demand or pressure-demand flow capabilities. The 9800
Series PCA, when used with a demand or demand/pressure-demand type 10100 Series
or 10800 Series Mask, will provide protection from hazardous smoke or fumes.
Page 1
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
807434, 9700, and 9800 Series Portable Cylinder Assembly (9800 Series PCA Pictured)
Figure 1/GRAPHIC-35-31-55-991-005-A01
SUBTASK 35-31-55-870-002-A01
B. Typical Installation
All 807434, 9700, and 9800 Series PCAs may be configured with a sling-type carrying
strap (harness) that attaches to the PCA. PCAs may be stored in convenient and
accessible locations on the aircraft. When the PCA must be secured in an aircraft,
optional lower (APN 36758-11) and upper (APN 36758-12, 22) Portable Cylinder
Bracket Assemblies are available. (Refer to SUBTASK 35-31-55-870-003-A01) for more
information on optional Portable Cylinder Bracket Assemblies.
The number of PCAs required on an aircraft is determined by applicable FARs, number
of passengers and the general flight profile of the aircraft.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-870-003-A01
C. Optional PCA Mounting Bracket Set
Bracket assemblies, sold and shipped separately as optional accessories, may be used
to secure certain PCA configurations within an aircraft.
A bracket set is made up of one lower bracket and one upper bracket. The lower
bracket (APN 36758-11 supports the base of the cylinder. Slots in the lower bracket
permit adjustability for mounting purposes. The upper bracket (APN 36758-12 or APN
36758-22), equipped with a quick release clamp or strap, secures the cylinder.
For additional information including availability and nominal dimensions of optional
Mounting Bracket Assemblies APN 36758-11, -12, -22, refer to AVOX Systems ACMM
35-37-58.
SUBTASK 35-31-55-870-004-A01
D. Technical Characteristics
NOTE : Leading particulars and weight data are subject to change without notice.
(1) 807434 and 9700 Series PCA
(a) (Refer to Table 1) and (Refer to Fig. 2) for the leading particulars (envelope
dimensions) of the 807434 and 9700 Series PCA.
(b) (Refer to Table 2) for the leading particulars (specific data) of the 807434
and 9700 Series PCA.
(c) (Refer to Table 3) for the weight data of the 807434 and 9700 Series PCA.
Page 3
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
CYLINDER & REGULATOR ASSEMBLY OUTLET ASSEMBLY
Callout Dimensions Callout Dimensions

Code in. (cm) Code in. (cm
(Refer to (Refer to
A B C D E Fig. 4) F
Fig. 4) (Max) (Max) (Typ) (Max) (Typ)
A 3.50 to 3.62 9.31 (23.64) 13.08 (33.22) 2.5 (6.4) 2.31 (5.86) A 2.50 (6.35)
(8.89 to 9.19)
B 3.50 to 3.62 13.44 (34.13) 17.5 (44.5) 2.5 (6.4) 2.31 (5.86) B 2.68 (6.83)
(8.89 to 9.19)
C 3.50 to 3.62 18.87 (47.93) 22.8 (57.91) 2.5 (6.4) 2.31 (5.86) C 3.13 (7.92)
(8.89 to 9.19)
D 3.50 to 3.62 9.31 (23.64) 13.08 (33.22) 2.5 (6.4) 2.31 (5.86) D 2.56 (6.50)
(8.89 to 9.19)
F 3.50 to 3.62 18.87 (47.93) 22.8 (57.91) 2.5 (6.4) 2.31 (5.86) K 0.81 (2.06)
(8.89 to 9.19)
G 3.50 to 3.62 18.88 (47.95) 22.8 (57.91) 2.5 (6.4) 2.29 (5.81) M 2.00 (5.08)
(8.89 to 9.19)
H 3.50 to 3.62 18.88 (47.95) 22.87 (58.08) 2.5 (6.4) 2.29 (5.81) N 2.25 (5.72)
(8.89 to 9.19)
S 2.22 (5.64)
PCA PN A B C D E
(Typ) (Max) (Max) (Typ) (Typ)
807434- 3.50 to 3.62 13.41 (34.06) 16.6 (42.2) 3.4 (8.6) 5.1 (13.0)
01 (8.89 to 9.19)
Table 1 / 807434 and 9700 Series PCA Leading Particulars (envelope dimensions)
Page 4
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
807434 and 9700 Series PCA Leading Particulars (envelope dimensions)

Figure 2/GRAPHIC-35-31-55-991-010-A01
Page 5
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
PCA Weight............................................................ (Refer to Table 3)

High Pressure Relief
– US DOT-3AA-1800 Steel Cylinder....................... 2650 - 2900 psig (18.27 - 20.00 MPa) and
160 - 165ºF (71.1 - 73.9ºC)
– US DOT-SP-8162-1850 Composite Cylinder or
– US DOT-SP-10915-1850 Composite Cylinder..... 2500 - 2775 psig (17.24 - 19.13 MPa)
Operating Pressure Range........................................ 150 - 1850 psig (1.03 - 12.76 MPa)
Operating Temperature Range................................. 5 to +158ºF (-15 to +71ºC)
Clamp Weight
– WWD-120 (APN 13160-00)................................... 0.069 lbs. (31.2 gm) each (used w/ 4.25, 7.15 and 11 cu ft
cylinders)
Regulator Assembly
Available Configurations
– 2 Outlet Ports........................................................ APNs 801160-00, -01, -03; 803199-04, 807433-02
– 3 Outlet Ports...................................................... APNs 801160-02, -04; 803199-05
Material of Construction
– Aluminum............................................................... APNs 801160-00, -01, -02 (After Apr 1/82, aluminum regulators
were not procurable and are not repairable, (Refer to Fig. 4 Sheet 1)
– Brass..................................................................... APNs 801160-03, -04; 803199-04, -05; 807433-02
Weight....................................................................... (Refer to Table 3)
Output Pressure....................................................... 55 ±2 psig (0.38 ±0.01 MPa)
Lock-up Pressure..................................................... 75 psig (0.52 MPa) maximum
(Outlet Pressure At Zero Flow)
Low Pressure Relief
– Free Flow Rate (nominal)..................................... 300 lpm NTPD at 135 psig (0.93 MPa)
– Opening Pressure................................................ More than 90 psig (0.62 MPa)
– Reseating Pressure............................................. Less than or equal to 90 psig (0.62 MPa)
Cylinder
– US DOT-3AA-1800................................................ Steel
– US DOT-SP-8162-1850 or Fiber-Wrapped Aluminum
US DOT-SP-10915-1850................................
Thread Size
– APN 6350A13-X-A, 6350A14-X-A, 6350A20-X-A 0.500 - 14 ANPT
Steel Cylinders...................
– APN 21507-06 or APN 805984-07 0.750 - 16UNF-2B
Composite Cylinder........................................
US DOT Approval Type
– Steel....................................................................... DOT-3AA-1800
– Composite.............................................................. DOT-SP-8162-1850 or DOT-SP-10915-1850
Maximum Gas Storage Pressure
– US DOT-3AA-1800 Steel Cylinder........................ 1800 psig (12.41 MPa) at 70ºF (21ºC)
– US DOT-SP-8162-1850 Composite Cylinder or 1850 psig (12.76 MPa) at 70ºF (21ºC)
– US DOT-SP-10915-1850 Composite Cylinder......
Service Life............................................................... Refer to chapter INSPECTION/CHECK.
Weight..................................................................... (Refer to Table 3)
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Accessories
Masks (Typical), Constant Flow Type
– DUO-SEAL® Mask.............................................. APN 28312 Series
– DUO-SEAL® Mask w/flow indicator and
microphone.................................
APN 28316 Series
– SKY MASK® w/ indicator.................................... APN 28314 Series
– Disposable Mask................................................. APN 28301 Series
– PAX Mask............................................................. APN 289-601 Series (Refer to CMM 35-22-26)
APN 289-701 Series (Refer to CMM 35-22-27)
PCA Mounting Bracket Set........................................ APNs 36758-11 and 36758-12, -22 (Refer to Paragraph 9.)
NOTE: DUO-SEAL® and SKY MASK® are registered Trademarks of AVOX Systems.
Table 2 / 807434 and 9700 Series PCA Leading Particulars (specific data)
CYLINDER AND REGULATOR ASSY HARNESS ASSY OUTLET ASSY

Cyl Weight Charged Weight
Cyl PN Regulator
(Maximum) (Maximum) Weight Weight
(Capacity in PN (Material) Part No. Part No.
Empty lbs. (Cyl & Reg Only) lbs. (gm) lbs. (gm)
cu ft / liters) (Note 1)
(kg) lbs. (kg)
6350A13-X-A 3.00 (1.361) 801160-00 5.11 (2.318) 801660-00 0.09 5009 0.05
(4.25 / 120) (Aluminum) (40.8) Series (22.7)
801160-03 5.99 (2.717)
(Brass)
6350A14-X-A 4.19 (1.901) 801160-04 7.19 (3.261) 801658-00 0.42 5041 0.09
(7.15 / 202) (Brass) (190.5) Series (40.8)
6350A20-X-A 5.25 (2.381) 801160-01 7.93 (3.597) 805118-01 0.60 5052-00 0.20
(11 / 311) (Aluminum) (272) (90.7)
801160-03 8.81 (3.996)
(Brass)
6350A13-X-A 3.00 (1.361) 801160-02 5.11 (2.318) 5507 0.09
(4.25 / 120) (Aluminum) Series (40.8)
801160-04 5.99 (2.717)
(Brass)
6350A20-X-A 5.25 (2.381) 801160-01 7.93 (3.597) 6818-01 0.01
(11 / 311) (Aluminum) (4.5)
801160-03 8.81 (3.996)
(Brass)
21507-06 2.40 (1.089) 803199-04 5.42 (2.460) 802856- 0.06
(11 / 311) (Brass) 01 (27.2)
21507-06 2.40 (1.089) 803199-05 5.42 (2.460) 36728-01 0.06
(11 / 311) (Brass) (Note 3) (27.2)
805984-07 1.80 (0.816) 807433-02 4.85 (2.199) 10008298 0.07
(7.15 / 202 (Brass) (31.8)
NOTE 1: After Apr 1/82 aluminum regulator assemblies listed in this column were not procurable and are not repairable.
Refer to Figure 2, Sheet 1.
NOTE 2: Outlet APN 36728-01 replaces outlet APN DPB153. After Jan 01/01 APN 36728-01 was not procurable.
Table 3 / 807434 Series and 9700 Series PCA Weight Data
Page 7
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(2) 9800 Series PCA

(a) (Refer to Table 4) and (Refer to Fig. 3) for the leading particulars (envelope
dimensions) of the 9800 Series PCA.
(b) (Refer to Table 5) for the leading particulars (specific data) of the 9800
Series PCA.
(c) (Refer to Table 6) for the weight data of the 9800 Series PCA.
CYLINDER & REGULATOR ASSEMBLY OUTLET ASSEMBLY
Callout Dimensions Callout Dimensions

Code in. (cm) Code in. (cm
(Refer A B C D E G H (Refer F
to Fig. (Max) (Max) (Typ) (Typ) (Max) (Max) to Fig. (Typ)
4) 4)
C 3.50 18.87 22.8 2.5 2.28 3.43 15.81 A 2.50 (6.35)
to 3.62 (47.93) (57.8) (6.4) (5.79) (8.71) (40.13)
(8.89 to
9.19)
D 3.50 18.87 22.8 2.5 2.28 3.43 15.81 B 2.69 (6.83)
to 3.62 (47.93) (57.8) (6.4) (5.8) (8.71) (40.13)
(8.89 to
9.19)
C 3.13 (7.92)
D 2.56 (6.50)
M 2.00 (5.08)
N 2.25 (5.72)
X 0.8 (2.0)
Table 4 / 9800 Series PCA Leading Particulars (envelope dimensions)
9800 Series PCA Leading Particulars (envelope dimensions)

Figure 3/GRAPHIC-35-31-55-991-015-A01
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
PCA Weight................................................................ (Refer to Table 6)

High Pressure Relief 2650 - 2900 psig (18.27 - 20.00 MPa) and 160 - 165ºF
(71.1 - 73.9ºC)
Operating Pressure Range........................................ 150 - 1800 psig (1.03 - 12.41 MPa)
Operating Temperature Range................................. -60 to +160ºF (-51 to 71ºC)
Clamp Weight
– WWD-120 (APN 13160-00)..................................... 0.069 lbs. (31.2 gm) each (used w/ 4.25, 7.15 and 11
cu ft cylinders)
Regulator Assembly
Available Configurations
– 2 Outlet Ports.......................................................... APNs 801160-01, -03
– 3 Outlet Ports.......................................................... APNs 801160-02, -04
– Aluminum................................................................ APNs 801160-01, -02, (After Apr 1/82, aluminum
regulators were not procurable and are not repairable,
(Refer to Fig. 4 Sheet 3)
– Brass....................................................................... APNs 801160-03, -04
Weight.......................................................................... (Refer to Table 6)
Output Pressure........................................................... 55 ±2 psig (0.38 ±0.01 MPa)
Lock-up Pressure........................................................ 75 psig (0.52 MPa) maximum
(Outlet Pressure At Zero Flow)
Low Pressure Relief
– Free Flow Rate (nominal).......................................... 300 lpm NTPD at 135 psig (0.93 MPa)
– Opening Pressure....................................................... More than 90 psig (0.62 MPa)
– Reseating Pressure..................................................... Less than or equal to 90 psig (0.62 MPa)
Cylinder
Material of Construction Steel
Thread Size
– APN 6350A20-X-A 0.500 - 14 ANPT
Cylinders...............................................
US DOT Approval Type DOT-3AA-1800
Maximum Gas Storage Pressure 1800 psig (12.41 MPa) at 70ºF (21ºC)
Service Life.................................................................... Refer to chapter INSPECTION/CHECK.
Weight............................................................................ (Refer to Table 6)
Respirator Regulator Assembly
Configurations
– Demand Type................................................ APNs 801242-01 and 801242-02
– Demand/Pressure-Demand Type.................. APNs 801242-03, -04
Inlet Pressure Range......................................... 35 - 60 psig (0.24 - 0.41 MPa)
Outlet Flow
– Demand Type................................................ 20 - 100 lpm NTPD at 35 - 60 psig (0.24 - 0.41 MPa)
– Demand, Pressure-Demand Type................. 20 - 100 lpm NTPD at 35 - 60 psig (0.24 - 0.41 MPa)
Accessories
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Masks (Typical)
– Demand, Demand/Pressure-Demand....... APNs 10100 and 10800 Series (Refer to CMM
35-10-71)
Constant Flow Type
– DUO-SEAL® Mask....................................................... APN 28312 Series
– DUO-SEAL® Mask w/flow indicator and microphone... APN 28316 Series
– SKY MASK® w/ indicator........................................... APN 28314 Series
– Disposable Mask......................................................... APN 28301 Series

– PAX Mask................................................................... APN 289-601 Series (Refer to CMM 35-22-26)
Bracket Assembly............................................. APNs 36758-11 and 36758-12 , -22 (Refer to
Paragraph 9.)
Table 5 / 9800 Series PCA Leading Particulars (specific data)
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RESPIRATOR REGULATOR CYLINDER AND REGULATOR ASSY

ASSY
Charged Weight
Cyl PN Cyl Weight Regulator
Weight (Maximum)
Part No. (Capacity in cu (Maximum) PN (Material)
lbs. (gm) (Cyl & Reg Only)
ft / liters) Empty lbs. (kg) (Note 1)
lbs. (kg)
801242-01 0.80 (363) 6350A20-X-A 5.25 (2.381) 801160-01 7.93 (3.597)
(11 / 311) (Aluminum)
801160-03 8.81 (3.996)
(Brass)
801242-02 0.70 (318) 6350A20-X-A 5.25 (2.381) 801160-02 7.93 (3.597)
(11 / 311) (Aluminum)
801160-04 8.81 (3.996)
(Brass)
801242-03 0.94 (426)
801242-04 0.91 (413)
HARNESS ASSY OUTLET ASSY

Part No. Weight Weight
Part No.
lbs. (gm) lbs. (gm)
801660-00 0.09 (40.8) 5009 Series 0.05 (22.7)
801658-00 0.42 (190.5) 5041 Series 0.09 (40.8)
5052-00 0.20 (90.7)
5507 Series 0.09 (40.8)
802856-01 0.06 (27.2)
36728-01 0.06 (27.2)

(Note 2)
6818-01 0.01 (4.5)
NOTE 1: After Apr 1/82 aluminum regulator assemblies listed in this column were not procurable and are not
repairable. Refer to Figure 4, Sheet 3.
NOTE 2: Outlet APN 36728-01 replaces outlet APN DPB153. After Jan 01/01 outlet APN DPB153 was not
procurable.
Table 6 / 9800 Series PCA Weight Data
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9700 Series PCA Matrix (Sheet 1 of 5)

Figure 4/GRAPHIC-35-31-55-991-020-A01
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AVOX SYSTEMS INC.
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Figure 4/GRAPHIC-35-31-55-991-020-A01
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Figure 4/GRAPHIC-35-31-55-991-020-A01
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Figure 4/GRAPHIC-35-31-55-991-020-A01
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Figure 4/GRAPHIC-35-31-55-991-020-A01
SUBTASK 35-31-55-870-005-A01
E. Part Number Identification for PN 9700 Series and PN 9800 Series PCAs
(Refer to Fig. 4) to identify part numbers of 9700 Series or 9800 Series PCAs.
Part numbers for the 9700 and 9800 Series PCA are made up of a basic series number
and callout codes for respirator regulator assembly (9800 Series only), cylinder and
regulator assembly, cylinder finish, harness assembly, outlet flow rate setting, outlet
altitude setting and outlet style.
(1) The basic series number identifies a specific PCA (either 9700 or 9800).
(2) The respirator regulator assembly callout code (9800 Series PCA only) identifies
a respirator regulator assembly part number.
(3) The cylinder and regulator assembly callout code identifies a cylinder part number
and regulator assembly (aluminum or brass construction) part number.
(4) The cylinder finish callout code identifies cylinder paint color.
(5) The harness assembly callout code identifies the part number of the harness
assembly that attaches to the PCA. Some harness assemblies may include one
or more passenger mask assemblies and mask stowage bags.
(6) The outlet flow rate setting callout code identifies the designated flow of oxygen
from a constant flow (metered) or full flow (non-metered) outlet type.
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(7) The outlet altitude setting callout code identifies the designated cabin altitude
of the outlet assembly.
(8) The outlet style callout code identifies the outlet assembly part number and outlet
type.
SUBTASK 35-31-55-807-006-A01
F. Part Number Guidelines for PN 9700 Series and PN 9800 Series PCAs
Provided below are important guidelines to identify part numbers for 9700 Series or
9800 Series PCAs and some examples of PCA configurations.
Where an ATA compliant PN is required, the procedure is to remove all dashes from
the AVOX Systems PN thus creating an identical PN with no dashes that is compliant
with the ATA Standard.
NOTE : This type of requirement applies to all PNs (that contain dashes in
the PCA Series).
ATA Compliant PN AVOX Systems PN

9700D1ABBF20B 9700-D1A-BBF20B
98009C1AF23AM 9800-9C1A-F23AM
Table 7 / Examples of ATA Compliant PNs Identical to AVOX Systems PN
(1) Outlet flow rate settings may be represented by one, two or three callout codes.
The 9700 Series PCA may have as many as three outlet flow rate setting callout
codes, however the 9800 Series PCA may only have a maximum of two outlet
flow rate setting callout codes. An outlet flow callout other than “ Full” are for
constant flow (metered) type outlet assemblies. An outlet flow callout of “Full” is
specified if the PCA is configured with only full flow (non-metered) type outlet
assemblies or a flow callout of “0” for a PCA configured with a plug.
(2) Outlet altitude setting is represented by only one callout code. A PCA configured
with either a full flow (non-metered) type outlet assembly or a plug must have an
altitude setting callout code of “0”. All other outlet types have an altitude setting
callout code greater than “0.”
(3) Outlet styles may have one or two callout codes. Three outlet types, a constant
flow (metered), full flow (non-metered) or plug can be used on a 9700 Series or
9800 Series PCA. Outlet assemblies attached to the PCA can only have one
outlet part number for a constant flow (metered) outlet type (e.g., 5009 Series) or
a full flow (non-metered) outlet type (e.g., 36728-01).
(4) Provided below are examples of some PCA configurations.
(a) PN 9700-B1X-BBF25A is a 9700 Series PCA with a PN 6084-02 cylinder,
PN 801160-04 regulator assembly, number 24062 green cylinder finish, no
harness assembly, two PN 5009-2-25 constant flow (metered) type outlet
assemblies and one PN 5009-4-25 constant flow (metered) type outlet
assembly designated for a cabin altitude of 25,000 ft (7,620 m).
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(b) PN 9700-F1A-BF10BN is a 9700 Series PCA with a PN 6084-01 cylinder,

either a PN 801160-02 aluminum regulator assembly or a PN 801160-04
brass regulator assembly, number 24062 green cylinder finish, PN
801660-00 harness assembly, one PN 5041-2-23 constant flow (metered)
type outlet assembly, one PN 5041-4-23 constant flow (metered) type
outlet assembly and one PN 36728-01 full flow (non-metered) type outlet
assembly. The constant flow (metered) outlet assemblies are designated for
a cabin altitude of 23,000 ft. (7,010 m).
(c) PN 9700-H2A-YY0N is a 9700 Series PCA with a PN 21507-06 cylinder,
PN 803199-05 brass regulator assembly, number 14187 green cylinder
finish, PN 801660-00 harness assembly, one 5041-2-10 outlet assembly,
one 5041-4-10 outlet assembly, and one 36728-01 full flow (non-metered)
type outlet assembly.
(d) PN 9800-2D1A-F20BM is a 9800 Series PCA with a PN 801242-02
demand type respirator regulator assembly, PN 6084-20 cylinder, either a
PN 801160-02 aluminum regulator assembly or a PN 801160-04 brass
regulator assembly, number 24062 green cylinder finish, PN 801660-00
harness assembly, one PN 5041-4-20 constant flow (metered) type outlet
assembly, one PN 802856-01 full flow (non-metered) type outlet assembly.
The constant flow (metered) outlet assembly is designated for a cabin
altitude of 20,000 ft (6,100 m).
(e) PN 9800-9C1A-E23A is a 9800 Series PCA with a PN 801242-04
demand/pressure-demand type respirator regulator assembly, PN 6084-20
cylinder, either a PN 801160-01 aluminum regulator assembly or a PN
801160-03 brass regulator assembly, number 24062 green cylinder finish,
PN 801660-00 harness assembly, one PN 5009-3-23 constant flow (metered)
type outlet assembly designated for a cabin altitude of 23,000 ft (7,010 m).
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TASK 35-31-55-870-802-A01
2. PORTABLE CYLINDER ASSEMBLY - OPERATION
The 807434 Series, 9700 Series, and 9800 Series PCAs are made up of a high-pressure
cylinder, regulator assembly, harness assembly, outlet assemblies and, on some
configurations, mask assemblies stored in fastener-mounted storage bags. The 9800 Series
also includes a respirator regulator assembly.
SUBTASK 35-31-55-870-007-A01
A. Harness Assemblies and Mask Assemblies Stored in Fastener-Mounted Storage Bags
(1) Most 9700 and 9800 Series PCAs use a harness assembly that is attached to the
cylinder with a clamp near the bottom and a loop around the regulator assembly,
allowing the unit to be carried by the user. Other harness configurations are
available and are typically attached to the cylinder using clamps at the top and
bottom of the cylinder.
(2) Typically, PAX mask assemblies are used with fastener-mounted storage bags
attached to the cylinder. The US FAA requires that at least one mask must be
connected at all times to each PCA onboard an aircraft for potential use (for
operators covered under 14 CFR Parts 25 and 121). Refer to chapter REWORK
for detailed AVOX recommendations for compliance.
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SUBTASK 35-31-55-870-008-A01
B. Respirator Regulator
(1) The 9800 Series PCA is configured with either a demand or
demand/pressure-demand type respirator regulator. The respirator regulator
(Refer to Fig. 5) is attached to the PCA regulator assembly (1 thru 3, IPL FIG.
7)) outlet port as shown. The demand type respirator regulator assembly allows
oxygen to flow, on demand, to a demand style mask assembly (e.g., 10100
Series).
Respirator Regulator Assembly (Demand Type Shown)

Figure 5/GRAPHIC-35-31-55-991-025-A01
WARNING : DO NOT USE THE PN 9800-8 OR PN 9800-9 SERIES PCA WITH THE
AVOX PN 10100 SERIES MASK ASSEMBLY. IF THE PN 9800-8 OR
PN 9800-9 SERIES PCA IS USED WITH THE AVOX PN 10100 SERIES
MASK ASSEMBLY, THE PCA MAY NOT PROVIDE OXYGEN FOR THE
FULL RATED DURATION CAUSING SERIOUS PERSONAL INJURY
OR DEATH.
(2) Inhalation of oxygen from the demand style mask assembly removes oxygen from
the body (11) of the respirator regulator through outlet port (6).
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(3) Removing oxygen from the body (11) causes a pressure drop allowing
atmospheric pressure, acting on the outside of the diaphragm (1), to move the
diaphragm inward against the stem of demand valve assembly (2). The action
of the diaphragm opens the demand valve assembly and oxygen flows from the
cylinder (5) through the regulator assembly (4) porting and enters the respirator
regulator assembly body (11), again raising the pressure in the body. Increased
pressure within the body moves the diaphragm away from the demand valve
assembly and stops the flow of oxygen.
(4) The demand/pressure-demand style respirator regulator assembly is similar to
the demand style respirator regulator assembly except that a slide button (7)
on case cover (9) allows the user to select demand for donning the mask and
pressure-demand modes when using the unit. In the pressured demand mode the
diaphragm is moved inward slightly by the action of a spring loaded plate and
lever assembly (10). The action of the plate and lever assembly creates a slight
excess in positive pressure within the pressure-demand mask assembly (e.g.,
10800 Series ) before the demand valve assembly stops the oxygen flow.
(5) The 10800 Series Positive Pressure Demand Mask Assembly, equipped with
compensated exhalation valve, is designed to be used with the pressure-demand
respirator regulator assembly only. The 10100 Series Demand Mask Assembly is
designed for use only with the demand respirator regulator assembly.
SUBTASK 35-31-55-870-009-A01
C. Cylinder
(1) The cylinder is a US Department of Transportation (DOT) & Transport Canada
(TC) rated pressure vessel that holds oxygen gas at a nominal working pressure of
1800 - 1850 psig (12.4 - 12.8 MPa). The cylinder is made of steel, or of seamless
aluminum that is wrapped either with Kevlar® fiber or carbon fiber in epoxy resin
base wrap with S-glass in epoxy resin overwrap and polyurethane top coating.
NOTE : Kevlar® is a Registered Trademark of E. I. du Pont de Nemours & Co.
(2) Refer to chapter INSPECTION/CHECK for information on the cylinder service life
and the hydrostatic test frequency requirements.
SUBTASK 35-31-55-870-010-A01
D. Regulator Assembly
(1) The single inlet regulator assembly is a multiple outlet device that lowers inlet
pressure from the cylinder to the outlet assemblies and to a respirator regulator
assembly (9800 Series PCA only). The regulator assembly has an on-off valve kit,
high-pressure gauge, relief valve assembly, safety outlet assembly, charging valve
assembly and various styles of outlet assemblies attached. A regulator assembly
may have a plug installed as an alternative to an outlet assembly.
(2) (Refer to Fig. 6) for a cross-sectional view of a regulator assembly shown in the
open (“ON”) position.
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(3) With the regulator assembly installed in the cylinder, and the handle (15) of the
on-off valve in the open position (fully counterclockwise) the head assembly (14)
is not seated on the high-pressure oxygen inlet orifice (13), allowing oxygen to
be supplied to the respirator regulator assembly (9800 Series PCA only) or the
outlet assemblies attached to the regulator assembly. Also, with the on-off valve
in the open position, the cylinder can be recharged.
(4) When the handle (15) is in the open position, high-pressure oxygen stored in the
cylinder passes into the inlet orifice (13). High-pressure oxygen and the spring
(4) push the thrust pin (7) upward against the seat assembly (6) preventing flow
through the regulator assembly while the opposite end of the thrust pin (7) acts
against a thrust plate (8) and diaphragm (9). One side of the diaphragm (9)
is acted upon by an adjusting spring (10) and the other side by the regulator
assembly outlet pressure.
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Regulator Assembly PN’s 801160-00 thru -04; 803199-04, -05; and 807433-02 (Cross Sectional
View)
Figure 6/GRAPHIC-35-31-55-991-030-A01
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(5) The adjusting spring (10) pushes the diaphragm (9) and thrust plate (8) downward
moving the thrust pin (7) away from the seat assembly (6). Increasing regulator
assembly outlet pressure then moves the diaphragm (9) upward, pushing against
the adjusting spring downward force. Oxygen will flow through the regulator
assembly when the force of the adjusting spring exceeds the regulator assembly
outlet pressure acting on the diaphragm and other forces tending to move the
thrust pin against the seat assembly.
(6) When the regulator assembly outlet pressure balances the adjusting spring (10)
force, the thrust pin is moved toward the seat assembly by high-pressure oxygen
and spring (4) until a condition of equilibrium is established and the regulator
assembly outlet pressure is maintained. The adjusting spring (10) is preset to
maintain a regulator assembly outlet pressure of approximately 55 psig (0.37
MPa).
SUBTASK 35-31-55-870-011-A01
E. Regulator Subassemblies
The following subassemblies attach to the regulator assembly.
(1) Charging valve assembly
(a) The charging valve assembly is used to fill the cylinder with high-pressure
oxygen. Because the charging valve assembly is located in the low-pressure
section of the regulator assembly, the on/off valve ( (Refer to IPL FIG.
7, 6 and 6A) must be open to allow oxygen to flow into the cylinder.
High-pressure oxygen applied to the charging valve assembly inlet ( Fig.
7),1) forces valve core (2) away from the seat in the charging valve assembly
body, and flows through porting into the oxygen cylinder.
(b) When high-pressure oxygen is removed from the charging valve assembly
the valve core moves toward the seat in the charging valve assembly body
and stops the flow of oxygen.
(c) A filler cap ( (Refer to IPL FIG. 7), 21 and 21A) prevents contamination of
the valve inlet and also provides a secondary seal.
(2) Relief Valve Assembly
(a) The relief valve assembly, installed in the low-pressure section of the
regulator assembly, protects the outlets from over-pressure. The relief valve
assembly will open and close as needed and is continuously available for
over-pressure conditions.
(b) Pressure greater than 90 psig (0.62 MPa) at the regulator assembly outlet
will force the poppet assembly ( (Refer to Fig. 8), 1) away from the seat (6)
in the body (2) of the relief valve assembly allowing oxygen to be vented
through an opening in the relief valve assembly body. When pressure at
the regulator assembly outlet is equal to or less than 90 psig (0.62 MPa) a
spring (3) forces the poppet against the seat and stops the flow of oxygen
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(3) Safety Outlet Assembly

(a) The safety outlet assembly ( (Refer to Fig. 6), 2) attaches to the regulator
and protects the cylinder from an over-pressure condition. The location of
the safety outlet assembly permits continuous operation so that at all times,
the cylinder is protected.
(b) The safety outlet assembly is a device that has a frangible safety disc
(3) that will rupture if the pressure inside a steel cylinder is greater than
approximately 2700 psig (18.62 MPa). The safety disc will rupture if the
pressure inside a composite cylinder is greater than approximately 2500
psig (17.24 MPa). If the safety disc releases pressure from inside the
cylinder, the safety disc must be replaced before the cylinder is ready for
operation or is ready for the charging mode.
(4) Outlet Assembly
(a) Seven different outlet assemblies and one outlet port plug are available for
use on the 9700 and 9800 Series PCA. Some outlet assemblies control the
flow rate of oxygen from the regulator assembly. Each outlet has an internal
check valve that permits oxygen flow from the regulator only when a mating
connector is attached to the outlet. (Refer to Fig. 10) for an illustration
of available outlet assemblies and their mating connectors. Other mating
connectors (not illustrated in Figure 10) are available for use with the outlet
assemblies shown.
(b) The outlet assembly and mating connector configurations allow a variety
of constant flow mask assemblies to be attached to the 9700 and 9800
Series PCA outlet assemblies. (Refer to Table 2) for accessory mask
assemblies for a 9700 Series PCA and (Refer to Table 5) for accessory
mask assemblies for a 9800 Series PCA.
(c) 9700 and 9800 Series PCAs use two different types of outlet assemblies, a
full flow (non-metered) type and constant flow (metered) type.
1 The full flow type outlet assembly contains only a check valve and
does not restrict oxygen flow from the regulator assembly when the
check valve is unseated. The full flow outlet assembly is used to
provide an unrestricted flow of oxygen at regulated pressure to a
downstream component, typically a mask-mounted regulator.
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2 The constant flow type outlet assembly, like the full flow type, also
contains a check valve which only allows oxygen flow when unseated.
Prior to November 1994, glass wool contained in the outlet assembly
was used to adjust oxygen flow at regulated pressure. Constant flow
type outlet assemblies containing glass wool media are referred to
as “adjustable” outlets and are no longer procurable. Beginning
in November 1994 the 5009-00, 5041-00, and 5507-00 constant
flow “adjustable” type outlet assemblies had product improvements
which incorporated fewer parts and eliminated the task of adjusting
the flow rate during testing. Constant flow type outlet assemblies
manufactured after November 1994 having a precision-drilled orifice
that controls oxygen flow rate and are referred to as “precision” outlets.
The precision outlet has replaced the adjustable outlet and has not
changed in either fit or function.
(d) Constant flow (metered) “precision” outlet assemblies have flow rate and
cabin altitude settings stamped into the exterior of the outlet body. In
addition to the flow rate and altitude settings stamps, the precision outlets
(manufactured after November 1994) have special markings on the outlet
body to help identify the outlet. (Refer to Fig. 9) for details of the special
markings stamped into the “precision” outlet body.
Charging Valve Assembly

Figure 7/GRAPHIC-35-31-55-991-035-A01
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Relief Valve Assembly

Figure 8/GRAPHIC-35-31-55-991-040-A01
5009, 5041 and 5507 Series Precision Outlet Assembly Markings

Figure 9/GRAPHIC-35-31-55-991-045-A01
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Outlet Assembly and Mating Connector Combinations

Figure 10/GRAPHIC-35-31-55-991-050-A01
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SUBTASK 35-31-55-870-012-A01
F. Overhaul Recommendations
Because of customer request, AVOX Systems overhaul recommendations for the
807434 Series, 9700 Series, 9800 Series, and 803668-01 PCA are included in the
INSPECTION/CHECK section of this manual. Refer to chapter INSPECTION/CHECK
for information on overhaul period, minimum necessary parts to replace, and kits of
minimum necessary parts to replace during an overhaul. Also included, is information
on necessary functional testing required after an overhaul.
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TESTING AND FAULT ISOLATION
TASK 35-31-55-700-801-A01
1. PORTABLE CYLINDER ASSEMBLY - TESTING
A. General
WARNING : STRICTLY OBEY THE PROCEDURES WHEN YOU DO WORK ON

THE OXYGEN SYSTEM. DO NOT USE OIL, GREASE OR OTHER
LUBRICANTS MADE FROM PETROL IN THE AREA OF OXYGEN
EQUIPMENT. YOU CAN CAUSE A FIRE OR EXPLOSION.
WARNING : ALL TEST EQUIPMENT MUST BE CALIBRATED DAILY BEFORE

THE FIRST HYDROSTATIC TEST. USE OF EQUIPMENT THAT IS
NOT CALIBRATED OR IS UNSERVICEABLE CAN CAUSE SERIOUS
INJURY OR DEATH.
WARNING : BE CAREFUL WHEN YOU USE EQUIPMENT THAT IS PRESSURIZED.

TOO MUCH PRESSURE OR DEFECTIVE EQUIPMENT CAN CAUSE
AN EXPLOSION AND RESULT IN SERIOUS INJURY OR DEATH.
CAUTION : INCREASE OR DECREASE THE SUPPLY PRESSURE SLOWLY ON

EACH OPERATION.
CAUTION : IN ALL THE PROCEDURES, GASEOUS OXYGEN IS SPECIFIED AS

THE TEST GAS. GASEOUS NITROGEN (A-A-59503 TYPE 1, CLASS
1, GRADE A STANDARD) OR DRY AND OIL-FREE AIR (CRITERIA:
TOTAL HYDROCARBON: WEIGHT LESS THAN 6 PPM IN VOLUME
- SOLID PARTICLES: LESS THAN 10 MICROMETERS - WATER
CONTENT: LESS THAN 5 MG/M3 AT ATMOSPHERIC AMBIANCE
(EQUIVALENT DEW POINT: -63 °C (-81 °F) AT 760 MMHG)) CAN
REPLACE THE GASEOUS OXYGEN. THEN, YOU MUST DO A
CONVERSION OF THE RESULTS BEFORE YOU COMPARE THEM
WITH THE RESULTS SPECIFIED FOR THE GASEOUS OXYGEN. DO
NOT USE OIL-PUMPED GAS.
(1) Reason for the Job

(a) Do these tests to make sure that the equipment is serviceable. You must
also do these tests if an equipment component or subassembly is replaced.
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B. Job Set-Up Information

(1) Special Tools, Fixtures and Equipment
(a) (Refer to Table 1001) for the special tools, fixtures and equipment necessary
to do the testing of the components.
NOTE : Tools, fixtures and equipment that you find to be equivalent can
be used as an alternative.
NOTE : Refer to chapter SPECIAL TOOLS, FIXTURES, EQUIPMENT
AND CONSUMABLES for full details.
PNR NAME RANGE ACCURACY SOURCE

No specific Mechanic standard tool NA NA Local supply
kit
1404 Series Pressure Gauge 0 - 100 psig (0 Minimum Ametek (US Gauge)
- 0.69 MPa) accuracy Sellersville, PA
0 - 200 psig (0 ±0.25% full 18960-2625
- 1.38 MPa) scale USA (V61349)
0 - 2000 psig
(0 - 13.8 MPa)
P4T Series Vent Valve NA NA Whitey Co.
B-4P4T4 0.250 in. - 18 ANPT Highland Heights, OH
Threads 44134-1533
USA (V12623)
44-1110 Series Test Regulator 0 - 2500 psig NA Tescom Corp.
44-1114 -24 (0 - 17.2 Elk River, MN
26-1600 Series MPa) Outlet 55330-2491
26-1612-24 Pressure USA (V5H642)
0 - 250 psig
(0 - 1.72
MPa) Outlet
Pressure
1110 Series Flowmeter 5.0 - 50 ccm Minimum Emerson Electric Co.
1110CC21ABGAA 13.6 - 136 ccm accuracy ±2% Brooks Instruments
1110CC11BBGAA 0.62 - 6.20 lpm full scale Division
1110CC71DBGAA 12.6 - 126 lpm Hatfield, PA 19440-3052
1110CJ42CBGAA USA (V91556)
5065-10 Mating Connector for NA NA Avox Systems (53655)
29559-00 5009-00, 5009 Series
14807-00 Outlet Assy
5067-08 5041-00, 5041 Series
36857-01 5507-00, 5077 Series
10007498 Outlet Assy
10003566, 5052-00
Outlet Assy
36728-01, DPB153
Outlet Assy
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PNR NAME RANGE ACCURACY SOURCE

1 Series Shut Off Valve (2 NA NA Whitey Co.
B-1VF4 required) Highland Heights, OH
44134-1533
USA (V12623)
18 Series Flow Control Valve NA NA Whitey Co.
B-18RF8 Highland Heights, OH
44134-1533
USA (V12623)
1 Series Needle Valve NA NA Whitey Co.
B-1RF4 Highland Heights, OH
44134-1533
USA (V12623)
803213-S58-12 Regulator Test Adapter NA NA Avox Systems (53655)
803213-S58-1 0.500 - 14 ANPT
Threads
0.750 - 16 UNF Threads
EW-34400-01 Graduated Cylinder - 5 NA NA Cole Parmer Instrument
cc Capacity Co.
Vernon Hills, IL
60061-1844
USA (VKB500)
16 Series - 16112J Low Pressure Regulator Vac to 2 psig Maximum inlet Fairchild Industrial
NOTE: REG requires (Vac to 14 pressure is Products Co.
both VAC and PRESS KPa) 250 psig (1.72 Winston-Salem, NC
to operate. (Vac to 55 in. MPa) 27103-6708
WC) USA (V07282)
2000 Series Draft Gauge -5.0 to +5.0 in. Minimum Dwyer Instruments Inc.
Magnehelic* WC (-12.7 to accuracy ±2% Michigan City, IN
2310-A-321 +12.7 cm WC) full scale 46360-0373
2015-A-321 Differential USA (V85274)
Pressure 0 to
15 in. WC (0 -
38 cm WC)
6210-00 Respirator Regulator NA NA Avox Systems (53655)
13822-00 Mating Coupling
Threaded Type - For
respirator regulator
assembly used on
9800-1 Series PCA or
AN Type
Quick Disc - For
assembly used on
9800-9 Series PCA
* Magnehelic is a Registered Trademark of Dwyer Instruments Inc.
Table 1001 / Testing - Special Tools, Fixtures and Equipment
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(2) Unless noted otherwise, flowmeters (Refer to Table 1001) are open to the
atmosphere at the outlet side (exhaust), and a draft gauge specified in a test
setup must be connected as follows.
(a) For suction pressure (negative pressure) measurements the test setup
connection must be placed on the port of the Draft Gauge labeled “low” or
“suction.” The other port (labeled “hi” or “pressure”) will be open to the
atmosphere.
(b) For pressure (positive pressure) measurements the test setup connection
must be placed on the port of the Draft Gauge labeled “hi” or “pressure.”
The other port (labeled “low” or “suction”) will be open to the atmosphere.
(3) Refer to chapter INSPECTION/CHECK for cylinder hydrostatic test requirements.
(4) Consumables
(a) (Refer to Table 1002) for the consumables necessary to do the testing of
the components.
NOTE : Consumables that you find to be equivalent can be used as
an alternative.
NAME PNR SOURCE

Oxygen MIL-PRF-27210, Type 1 Local supply
Air BB-A-1034, Source 2, Grade A Local supply
Nitrogen BB-N-411B, Type 1, Class 1, Grade A Local supply
Thread Sealing Tape PTFE Ribbon Tape Local supply
0.250 in. (0.635 cm) wide CID A-A-58092, size 1
Leak Detection Compound, Oxygen MIL-PRF-25567, Type I Local supply

Systems
Table 1002 / Testing - Consumables
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(5) Reference Documents

(a) (Refer to Table 1003) for a list of applicable reference documents.
DOCUMENT NAME DOCUMENT NUMBER

Aviators Breathing Oxygen Purity Standard AS8010
Commercial Item Description Tape Antiseize, Polytetrafluoroethy- A-A-58092
lene
Oxygen, Aviator’s Breathing, MIL-PRF-27210

Liquid and Gas
Federal Specification, Nitrogen, Technical A-A-59503
Military Specification MIL-PRF-25567
Leak Detection Compound
Oxygen Systems
Standard Test Method for Leaks Using Bubble Emission ASTM E 515-05
Techniques
Methods for Pressure Testing CGA C-1
Compressed Gas Cylinders
Table 1003 / Testing - Reference Documents
C. Test Configuration
(1) Do all tests under the standard conditions of test laboratory:
Ambient temperature . . . . . . . . . . . . . . . . . 59° to 95° F (15° to 35° C)
Barometric pressure . . . . . . . . . . . . . . . . . 27 -32 in. Hg (686 - 813 mm. Hg)
Relative humidity . . . . . . . . . . . . . . . . . . . . 5 - 95%
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TASK 35-31-55-700-802-A01
2. Relief Valve Assembly Test
(Refer to Fig. 1001), (Refer to Table 1001) and (Refer to Table 1002).
A relief valve which does not pass the following test must be replaced.
SUBTASK 35-31-55-790-001-A01
A. Leakage
(1) Close the Vent Valve and slowly apply a pressure of 90 psig (0.62 MPa) to the
relief valve assembly. There must be zero leakage from the relief valve assembly.
No bubbles in the Leak Detection Compound at the relief valve assembly outlet is
an indication of zero leakage.
SUBTASK 35-31-55-720-001-A01
B. Flow
(1) Remove the relief valve assembly from the Leak Detection Compound and apply
135 psig (0.93 MPa) to the relief valve assembly. The relief valve assembly must
allow oxygen to flow freely through the outlet opening.
SUBTASK 35-31-55-790-002-A01
C. Pressure to Close
(1) Lower the inlet pressure to 89 psig (0.61 MPa), the relief valve assembly must
reseat. Immerse the relief valve assembly in Leak Detection Compound. There
must be zero leakage from the relief valve assembly.
(2) Reduce oxygen supply pressure to 0 psig (0 MPa) and remove the relief valve
assembly from the test setup. Dry relief valve assembly in clean, dry air.
Relief Valve Assembly Test Setup

Figure 1001/GRAPHIC-35-31-55-991-055-A01
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TASK 35-31-55-700-803-A01
3. Outlet Assembly Test
Test applies to all outlet assemblies unless noted otherwise.
(Refer to SUBTASK 35-31-55-870-011-A01) to determine if a constant flow (metered) outlet
assembly is an “adjustable” type ( (Refer to IPL FIG. 1) or (Refer to IPL FIG. 1B), 300,
310, 320, 325; (Refer to IPL FIG. 1A), 300, 310, 325) or a “precision” type ( (Refer to IPL
FIG. 1), (Refer to IPL FIG. 1A) or (Refer to IPL FIG. 1B), 305, 315, 330; (Refer to IPL FIG.
7), 70 and 75).
SUBTASK 35-31-55-790-003-A01
A. Full Flow (non-metered) Outlet Assemblies
CAUTION : FAILURE TO DISCONNECT THE FLOWMETER WHILE TESTING A

FULL-FLOW OUTLET ASSEMBLY MAY DAMAGE THE FLOWMETER
BECAUSE OF THE HIGH FLOW RATE OR PRESSURE POSSIBLE.
(1) Disconnect the Flowmeter from the test setup.

(2) Plug the outlet side of the applicable Mating Connector.
(3) Apply Leak Detection Compound to the connection between the outlet assembly
( (Refer to IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, , 335 thru 355 as
applicable; IPL FIG. 8), -1) and the Mating Connector. Adjust the Test Regulator
to a pressure of 125 psig (0.862 MPa), as indicated on the Pressure Gauge.
(4) There must be no leakage between the outlet assembly and the Mating Connector.
Bubbles from the Leak Detection Compound are an indication of leakage.
(5) Reduce pressure to 55 ±2 psig (0.38 ±0.014 MPa).
(6) Disengage the Mating Connector from the outlet assembly, then engage.
Disengage and engage a total of five times. The outlet assembly must not bind,
stick or malfunction.
(7) Reduce pressure to 0 psig (0 MPa). Remove the outlet assembly from the test
setup and dry using clean, dry, oil-free air.
(8) Repeat steps (1) thru (7) for each full-flow outlet assembly.
(9) Connect the Flowmeter (previously removed) to the test setup.
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Outlet Assembly Test Setup

Figure 1002/GRAPHIC-35-31-55-991-060-A01
SUBTASK 35-31-55-790-004-A01
B. Leak Test of Test Setup for Constant Flow (Metered) Outlet Assemblies
NOTE : Leaks in the test setup may cause errors in the measured flow rates.
Prior to testing constant flow (metered) outlet assemblies the test setup must be
checked for leaks. Leaks in the test setup may cause errors in the measured flow rates.
(1) Apply Leak Detection Compound to all connections in the test setup between the
Mating Connector and the Flowmeter.
(2) Apply 55 ±2 psig (0.38 ±0.014 MPa) pressure to the outlet assembly ( (Refer to
IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, , 300 thru 355 as applicable; , IPL
FIG. 3, , -1 thru -1K; , IPL FIG. 4, , -1 thru -1K; , IPL FIG. 5, , 1 thru -1G; , IPL
FIG. 6, , -1; IPL FIG. 7), 70 and 75).
(3) There must be no leakage between the Mating Connector and the Flowmeter.
(4) Tighten any connections that leak.
(5) Reduce inlet pressure to 0 psig (0 MPa).
SUBTASK 35-31-55-720-002-A01
C. “Precision” Type Constant Flow (metered) Outlet Assemblies
and the Mating Connector.
(2) Apply 55 ±2 psig (0.38 ±0.014 MPa) to the outlet assembly ( (Refer to IPL FIG.
1, , IPL FIG. 1A, and , IPL FIG. 1B, , 305, 315, 330 as applicable; , IPL FIG. 3,
, -1A thru -1K; , IPL FIG. 4, , -1A thru -1K; , IPL FIG. 5, , -1A thru -1G; IPL
FIG. 7), 70 and 75).
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(4) Read the flow rate on the Flowmeter. The flow rate must be within the required
flow rate range (Refer to Table 1004). If the ground level flow rate for the outlet
assembly is not within the Minimum – Maximum range for the required ground
level flow rate, the outlet assembly must be replaced.
NOTE : Specifications given in Table 1004 correspond to flow rate and altitude
settings marked on the outlet assembly being tested.
(6) Reduce inlet pressure to 0 psig (0 MPa). Remove the outlet assembly from the
test setup and dry using clean, dry, oil-free air.
(7) Repeat steps (1) thru (6) for each “precision” type constant flow outlet assembly.
Outlet Flow Rate Setting Altitude Setting (shown on outlet body)

(shown on outlet body) ft x 1000 (m x 1000)
lpm at STPD 10 (3.05) 20 (6.10) 23 (7.01) 25 (7.62)
Required Ground Level Flow Rate
(Min – Max)
lpm at NTPD
2 2.47 – 2.73 2.66 – 2.94 2.66 – 2.94 2.66 – 2.94
3 N/A 3.90 – 4.30 3.90 – 4.30 3.90 – 4.30
4 4.75 – 5.25 4.94 – 5.46 4.94 – 5.46 4.94 – 5.46
How To Use This Table
1. Find the outlet flow rate setting in the left column (e.g., 2 lpm). :
2. Follow the row across to the altitude setting (e.g., 23,000 feet or 7,010 meters).
3. Make sure that the measured flow rate of the outlet assembly under test is within the Min – Max range for the
Required Ground Level Flow Rate (e.g., 2.66 - 2.94 lpm).
NOTE: N/A indicates that this combination of flow rate setting and altitude setting is not available in a precision
outlet.
Table 1004 / Flow Rate Requirements for Precision Outlet Assembly
SUBTASK 35-31-55-720-003-A01
D. “Adjustable” Type Constant Flow (Metered) Outlet Assemblies
and the Mating Connector.
(2) Apply 55 ±2 psig (0.38 ±0.014 MPa) to the outlet assembly ( (Refer to IPL FIG. 1
and , IPL FIG. 1B, , 300, 310, 320, 325; , IPL FIG. 1A, , 300, 310, 325; , IPL FIG.
3, , , IPL FIG. 4, , , IPL FIG. 5, and IPL FIG. 6), -1).
(4) Read the flow rate on the Flowmeter. The flow rate must be within the required
flow rate range (Refer to Table 1005).
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(a) If the ground level flow rate for the outlet assembly is within the required
flow range (Refer to Table 1005), proceed to Step 5.
(b) If the ground level flow rate is not within the required flow range (Refer to
Table 1005), discard the “adjustable” type outlet assembly and replace with
a “precision” type outlet assembly. Refer to (Refer to Fig. 4) to select the
proper “precision” type outlet assembly.
NOTE : “Adjustable” type outlet assemblies are not procurable and have been
replaced by “precision” type outlet assemblies. “Precision” type outlet
assemblies require no adjustment.
(6) Reduce the inlet pressure to 0 psig (0 MPa). Remove the outlet assembly from
the test setup and dry using clean, dry, oil-free air.
(7) Repeat steps (1) thru (6) for each “adjustable” type constant flow outlet assembly.
Outlet Flow Rate Setting Altitude Setting (shown on outlet body)

(shown on outlet body) ft x 1000 (m x 1000)
lpm at STPD
10 (3.05) 20 (6.10) 23 (7.01) 25 (7.62)
Required Ground Level Flow Rate
(Min – Max)
lpm at NTPD
2 2.50 – 2.76 2.64 – 2.92 2.68 – 2.96 2.70 – 2.98
3 3.66 – 4.04 3.85 – 4.25 3.91 – 4.33 3.94 – 4.36

4 4.72 – 5.22 4.94 – 5.46 5.00 – 5.52 5.04 – 5.58
How To Use This Table
1. Find the outlet flow rate setting in the left column (e.g., 2 lpm). :
2. Follow the row across to the altitude setting (e.g., 23,000 feet or 7,010 meters).
3. Make sure that the measured flow rate of the outlet assembly under test is within the Min – Max range for the
Required Ground Level Flow Rate (e.g., 2.68 - 2.96 lpm).
Table 1005 / Flow Rate Requirements for Adjustable Outlet Assembly
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TASK 35-31-55-700-804-A01
4. Respirator Regulator Tests
(Refer to IPL FIG. 2) unless noted otherwise.
These tests apply to all respirator regulators (1 thru 3) unless noted otherwise.
For demand/pressure-demand respirator regulator (3), put the slide button (12D) on the case
cover (14) in the demand mode unless noted otherwise.
SUBTASK 35-31-55-790-005-A01
A. Demand Valve Assembly Leakage
(1) Observe the Pressure Gauge and apply 35 psig (0.24 MPa) pressure to the
respirator regulator inlet.
(2) Measure the leakage (if present) from the demand valve assembly ( (Refer to IPL
FIG. 1B, 830; IPL FIG. 2), 20) with the Flowmeter. Leakage must not be more
than 10 ccm NTPD.
(3) Increase the inlet pressure to 75 psig (0.52 MPa). The demand valve assembly
leakage (if present) must not be more than 10 ccm NTPD.
(4) Reduce the inlet pressure to 0 psig (0 MPa) and remove the respirator regulator
from the test setup.
Demand Valve Assembly Leakage Test Setup

Figure 1003/GRAPHIC-35-31-55-991-065-A01
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SUBTASK 35-31-55-790-006-A01
B. Inward Leakage Test
NOTE : (Refer to Fig. 1004), (Refer to Table 1001) and (Refer to Table 1002).
(1) Seal the respirator regulator inlet port.
(2) Apply a negative pressure of 1 in. WC, as indicated on Draft Gauge, to the outlet
of the respirator regulator.
(3) Leakage, as measured on the Flowmeter, must not be more than 100 ccm NTPD.
SUBTASK 35-31-55-790-007-A01
C. Outward Leakage Test
(1) Seal the respirator regulator inlet port.
(2) Apply a positive pressure of 12 in. WC, as indicated on the Draft Gauge, to
the outlet of the respirator regulator.
(3) Leakage, as measured on the Flowmeter, must not be more than 100 ccm NTPD.
Inward/Outward Leakage Test Setup

Figure 1004/GRAPHIC-35-31-55-991-070-A01
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SUBTASK 35-31-55-720-004-A01
D. Flow Test
(1) Demand type regulators
(a) Close the Shut Off Valve, Flow Control Valve and Needle Valve.
(b) Observe the Pressure Gauge and slowly apply 40 psig (0.28 MPa) pressure
to the inlet of the respirator regulator ( (Refer to IPL FIG. 2), -1 and -2).
(c) Apply vacuum to the test setup.
(d) Slowly adjust the Flow Control Valve until Flowmeter No. 2 indicates a
flow of 20 lpm NTPD.
(e) Carefully open the Shut Off Valve. Compare the respirator regulator outlet
suction pressure indicated on the Draft Gauge with requirements (Refer to
Table 1006). The suction pressure indicated on the draft gauge must be
less negative than the value in Table 1006 in order to pass.
(f) Repeat steps (a) thru (e) for all flow rates (at inlet pressures).
(g) Close the vacuum source and reduce the inlet pressure to 0 psig (0 MPa).
Flow Test Setup

Figure 1005/GRAPHIC-35-31-55-991-075-A01
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REGULATOR OUTLET MAX OUTLET SUCTION

REG INLET PRESSURE psig (MPa) FLOW RATE lpm at PRESSURE in. WC
NTPD (REFER TO NOTE)
40 (0.28) 20 -0.75
70 -1.55
100 -2.00
60 (0.41) 20 -0.75
70 -1.55
100 -2.00
NOTE: A value more negative than the maximum pressure given constitutes a failure.
Table 1006 / Flow Test Requirements for Demand Mode Respirator Regulators
(2) Pressure-Demand type respirator regulator.

NOTE : (Refer to IPL FIG. 2) unless indicated otherwise.
NOTE : This test applies only to pressure-demand type respirator regulators.
(a) Put the slide button (12D) on the case cover (14) in the pressure-demand
mode.
(b) Close Shut Off Valve, Flow Control Valve and Needle Valve.
(c) Observe the Pressure Gauge and slowly apply 40 psig (0.28 MPa) pressure
to the inlet of the respirator regulator.
(d) Apply vacuum to the test setup.
(e) Open the Shut Off Valve. Slowly adjust the Flow Control Valve until
Flowmeter No. 2 indicates a flow of 20 lpm NTPD.
(f) Compare the respirator regulator outlet pressure indicated on the Draft
Gauge with the requirements (Refer to Table 1007).
WARNING : FAILURE TO WEAR GLOVES WHEN BENDING COMPRESSION

SPRING MAY RESULT IN INJURY TO THE HANDS.
(g) If the outlet pressure indicated on the Draft Gauge is not in agreement with
the requirements found in Table 1007, adjust the compression spring (12A).
NOTE : Carefully and in small increments, bend the ends of the compression
spring (12A) closer together (inward) to reduce the outlet pressure or
farther apart (outward) to increase the outlet pressure.
(h) Repeat steps (a) thru (f) for a flow rate of 100 lpm NTPD (at inlet pressures)
given in Table 1007.
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(i) Close the Flow Control Valve.

(j) Slowly adjust the Needle Valve until Flowmeter No. 1 indicates a flow of
0.01 lpm NTPD.
(k) Compare the respirator regulator outlet pressure indicated on the Draft
Gauge with the requirements found in Table 1007 for the respirator regulator
inlet pressures of 40 and 60 psig (0.28 and 0.41 MPa).
(l) Close the vacuum source and reduce the inlet pressure to 0 psig (0 MPa).
REGULATOR OUTLET
ALLOWABLE OUTLET PRESSURE
REG INLET PRESSURE psig (MPa) FLOW RATE lpm at
in. WC
NTPD
40 (0.28) 20 +0.5 to +2.0
100 +0.5 to +2.0
0.01 +0.5 to +2.5
60 (0.41) 20 +0.5 to +2.0
100 +0.5 to +2.0
0.01 +0.5 to +2.5
Table 1007 / Flow Test Requirements for Pressure-Demand Mode Respirator Regulators
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TASK 35-31-55-780-801-A01
5. Regulator Assembly Outlet Pressure Test
The regulator assembly must have the output pressure set correctly and checked for
repeatability so that the outlet assemblies will provide the required flows.
A. Test Procedure
(1) Make sure that the on/off valve kit ( (Refer to IPL FIG. 7), 6, 6A) is in the closed
position (fully clockwise). Insert the appropriate Mating Connector into any outlet
assembly and discharge any pressure remaining in the regulator assembly.
Remove the Mating Connector.
(2) Remove the relief valve assembly (37) and install the Pressure Gauge (35, 36).
(3) Remove one outlet assembly ( (Refer to IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG.
1B, , 300 thru 355; , IPL FIG. 3, , -1 thru -1K; , IPL FIG. 4, , -1 thru -1K; , IPL
FIG. 5, , -1 thru -1G; , IPL FIG. 6, , -1; , IPL FIG. 7, , 70 and 75; , IPL FIG. 8, ,
-1); or plug (, IPL FIG. 1, , , IPL FIG. 1A, and , IPL FIG. 1B, , 360 and 365) from
the body ( IPL FIG. 7), 55 thru 61). Connect the Needle Valve and Flowmeter
where the outlet assembly or plug was removed. Close the Needle Valve.
(4) Apply 1800 psig (12.41 MPa) pressure to the inlet of the regulator assembly.
(5) Rotate the handle (8) counterclockwise to open the on-off valve kit ( (Refer
to IPL FIG. 7), 6, 6A).
(6) Carefully open and adjust the Needle Valve until the Flowmeter indicates 4.0
lpm SLPM.
(7) The regulator assembly output pressure, as indicated on the Pressure Gauge,
must be 55 ±2 psig (0.38 ±0.014 MPa). If necessary, adjust the regulator output
pressure as follows.
NOTE : After the initial regulator output pressure adjustment is made at 55 ±2
psig (0.38 ±0.014 MPa), further adjustments are to be made only
if noted.
(a) If necessary, Refer to chapter DISASSEMBLY to remove the screws (39,
39A; or (Refer to IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, , 805) and
identification plate ( IPL FIG. 7), 38) from the case (41, 41A).
(b) Turn the setscrew (40, 40A) until the Pressure Gauge indicates 55 ±2 psig
(0.38 ±0.014 MPa).
NOTE : Turn the setscrew in (clockwise) to increase the output pressure.
AVOX recommends that the pressure be set near 57 psig (0.39
MPa) initially.
(8) Put the on-off valve kit (6, 6A) in the closed position, then in the open position.
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(9) Observe the flow indicated on the Flowmeter and adjust, if necessary, to 4.0 lpm
using the Needle Valve. With a flow rate set at 4.0 lpm the regulator assembly
output pressure, as indicated on the Pressure Gauge, must be 55 ±2 psig (0.38
±0.014 MPa).
(10) Repeat steps (8) and (9) ten times. With a flow rate set at 4.0 lpm the regulator
assembly output pressure, as indicated on the Pressure Gauge, must be 55 ±2
psig (0.38 ±0.014 MPa).
(11) Close the Needle Valve and make sure that the flow indicated on the Flowmeter
is 0 lpm.
(12) The pressure indicated on the Pressure Gauge must be less than or equal to 75
psig (0.52 MPa).
(13) Allow the regulator assembly to remain pressurized for 24 hours. Repeat step (9).
(14) If necessary, refer to step (7) and adjust the regulator outlet pressure to 55 ±2
psig (0.38 ±0.014 MPa).
(15) Repeat steps (8) thru (12).
(16) Reduce the regulator assembly inlet pressure to 0 psig (0 MPa). Open the Needle
Valve and discharge any pressure remaining in the regulator assembly.
(17) Remove the Needle Valve and Pressure Gauge from the regulator assembly.
(18) Refer to chapter ASSEMBLY of this manual and reinstall the outlet assembly (
(Refer to IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, , 300 thru 355; , IPL FIG.
3, , -1 thru -1K; , IPL FIG. 4, , -1 thru -1K; , IPL FIG. 5, , -1 thru -1G; , IPL FIG. 6,
, -1; , IPL FIG. 7, , 70 and 75; , IPL FIG. 8, , -1); or plug (, IPL FIG. 1, , , IPL FIG.
1A, and , IPL FIG. 1B, , 360 and 365), screws (, IPL FIG. 7, , 39 and 39A or ,
IPL FIG. 1, , , IPL FIG. 1A, and , IPL FIG. 1B, , 805) and identification plate (
IPL FIG. 7), 38) previously removed.
Output Pressure Test Setup

Figure 1006/GRAPHIC-35-31-55-991-080-A01
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-780-802-A01
6. Gauge Accuracy Test
(Refer to IPL FIG. 7) unless noted otherwise.
A. Test Procedure
(1) Close the Vent Valve.
(2) Apply 1800 psig (12.41 MPa) pressure to the test setup, as indicated on the
Pressure Gauge. The pressure indicated on the gauge (35, 36, 36A) must be
within ±75 psig (±0.52 MPa) of pressure indicated on the test setup Pressure
Gauge.
(3) Repeat step B at test setup pressure of 1000 psig (6.89 MPa). The pressure
indicated on the gauge (35, 36, 36A) must be within ±75 psig (±0.52 MPa) of the
pressure indicated on the test setup Pressure Gauge.
(4) Reduce the inlet pressure of the test setup to 0 psig (0 MPa). The pressure
indicated on the gauge (35, 36, 36A) must be within ±75 psig (±0.52 MPa) of the
pressure indicated on the test setup Pressure Gauge.
(5) Open the Vent Valve and remove the gauge (35, 36, 36A).
Gauge Accuracy Test Setup

Figure 1007/GRAPHIC-35-31-55-991-085-A01
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TASK 35-31-55-700-805-A01
7. On-Off Valve Kit Torque Test
(Refer to IPL FIG. 7) for item numbers in parentheses () unless noted otherwise.
A. Test Procedure
(1) Refer to chapter DISASSEMBLY and remove the identification plate (7), flange
hex nut (9C), handle (8), spring washer (11) and flat washers (12) from the on-off
valve kit (6, 6A).
(2) Apply 1800 psig (12.41 MPa) to the inlet of the regulator assembly (1 thru 5).
(3) Using the torque wrench, rotate the stem (15, 15A) counterclockwise one full turn.
The torque required to rotate the stem one full turn must not be more than 16
in-lbs (1.8 N.m).
(4) Using the torque wrench, and applying a torque of not more than 16 lbf-in. (1.8
N.m), rotate the stem (15, 15A) clockwise until the on-off valve kit (6, 6A) is closed.
(5) Attach the appropriate Mating Connector to any outlet assembly and discharge
any pressure remaining in the regulator assembly.
(6) Attach the hose connecting the Graduated Cylinder and the Mating Connector.
Leakage, if present, must not be more than 5 cc in one hour.
(7) Remove the hose connecting the Graduated Cylinder and the Mating Connector.
Remove the Mating Connector from the outlet assembly.
(8) Refer to chapter ASSEMBLY and install the identification plate (7), flange hex nut
(9C), handle (8), spring washer (11), and flat washers (12) previously removed.
NOTE : The nut (9, 9A) and washer (10, 10A) are not procurable. The
self-locking hex nut (9C) replaces the nut (9, 9A, 9B) and washer
(10, 10A).
On-Off Valve Kit Torque Test Setup

Figure 1008/GRAPHIC-35-31-55-991-090-A01
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TASK 35-31-55-700-806-A01
8. PCA Final Test
(Refer to IPL FIG. 7) for item numbers in parentheses () unless noted otherwise.
Make sure the PCA is fully charged (1800 psig (12.41 MPa) minimum) before testing for
external leakage. Refer to chapter ASSEMBLY for PCA charging procedure.
SUBTASK 35-31-55-790-008-A01
A. External leakage
(1) Apply Leak Detection Compound to all PCA external surfaces.
(2) Rotate the handle (8) counterclockwise to open the on-off valve (6, 6A).
(3) External leakage from all PCA external surfaces must be zero. Bubbles from the
Leak Detection Compound are an indication that the PCA is leaking.
(4) Perform a latent leakage test. (Keep the on/off valve in the open position for 24
hours and recheck the PCA for external leakage.)
(a) Why do a Latent Leak Test?
1 The purpose of the latent test is to determine if the unit will leak in
the future.
2 This is done by doing a leak test two times.
3 The first leak test is done right after re-filling the cylinder (PCA
Charging Procedure).
4 The second test is done after a waiting period of 24 hours.
5 The waiting period allows the cylinder assembly to completely reach a
stable temperature and is an indication of the integrity of the repair
of overhaul actions.
(b) When To Do a Latent Leak Test
1 The latent leak test is only done after a cylinder assembly has been
repaired, overhauled or been hydrostatically tested.
2 If a cylinder assembly has been trans-filled but not repaired,
overhauled or disassembled, then a latent leak test is not required.
(5) Put the on/off valve (6, -6A) in the closed position. Insert the applicable Mating
Connector into any outlet assembly and discharge any remaining pressure in the
regulator assembly. Remove the Mating Connector.
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SUBTASK 35-31-55-720-005-A01
B. Functional Test
(1) Perform a functional test of the PCA by connecting an appropriate mask to each
outlet assembly to assure the flow of oxygen.
(2) Additionally, if the PCA is a 9800 Series equipped with a respirator regulator
assembly ( (Refer to IPL FIG. 1B), 30 thru 45), connect a demand type or
demand/pressure-demand type mask assembly (as appropriate - (Refer to
SUBTASK 35-31-55-870-008-A01)) to the respirator regulator assembly (30 thru
45). Don (place on face) the mask assembly and breathe to assure the flow of
oxygen.
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TASK 35-31-55-810-801-A01
9. Fault Isolation and Troubleshooting
A. Fault Isolation Table
(1) (Refer to Table 1008) for troubleshooting problems, causes, and solutions.
TROUBLE PROBABLE CAUSE SOLUTION

RELIEF VALVE ASSEMBLY TEST
Relief valve assembly ( (Refer to IPL Malfunctioning or damaged relief Replace relief valve assembly.
FIG. 7), 37) operation pressure is out valve assembly.
of limits.
OUTLET ASSEMBLY TEST
Outlet assembly ( (Refer to IPL FIG. 1), Outlet assembly and mating Disconnect and reconnect outlet
(Refer to IPL FIG. 1A) and (Refer to IPL connector not connected assembly and mating connector.
FIG. 1B), 300 thru 355; (Refer to IPL properly.
FIG. 3), -1 thru -1K; (Refer to IPL FIG.
Mating connector worn or Replace mating connector.
4), -1 thru -1K; (Refer to IPL FIG. 5),
damaged.
-1 thru -1G; (Refer to IPL FIG. 6), -1;
(Refer to IPL FIG. 7), 70 and 75; (Refer Outlet assembly worn or Replace worn parts or replace
to IPL FIG. 8), -1) leaks at connection to damaged. outlet assembly.
mating connector.
Outlet assembly ( (Refer to IPL FIG. 1), Contaminated, worn or damaged If a "precision" type outlet
(Refer to IPL FIG. 1A) and (Refer to IPL outlet assembly. assembly, clean, or replace outlet
FIG. 1B), 300 thru 355; (Refer to IPL assembly.
FIG. 3), -1 thru -1K; (Refer to IPL FIG. If an "adjustable" type outlet
4), -1 thru -1K; (Refer to IPL FIG. 5), -1 assembly, discard and replace
thru -1G; (Refer to IPL FIG. 6), -1; (Refer with a "precision" type outlet
to IPL FIG. 7), 70 and 75; (Refer to IPL assembly.
FIG. 8), -1) flow rate is out of limits.
Connection between outlet assembly ( Outlet assembly and mating Clean or replace outlet assembly
(Refer to IPL FIG. 1), (Refer to IPL FIG. connector contaminated, worn or mating connector.
1A) and (Refer to IPL FIG. 1B), 300 thru or damaged.
355; (Refer to IPL FIG. 3), -1 thru -1K;
(Refer to IPL FIG. 4), -1 thru -1K; (Refer
to IPL FIG. 5), -1 thru -1G; (Refer to IPL
FIG. 6), -1; (Refer to IPL FIG. 7), 70
and 75; (Refer to IPL FIG. 8), -1) and
mating connector is binding, sticking or
malfunctioning.
DEMAND VALVE ASSEMBLY LEAKAGE TEST
Demand valve assembly ( (Refer to IPL Demand valve assembly worn, Replace demand valve assembly.
FIG. 2), 20; (Refer to IPL FIG. 1B), 830) binding or damaged.
leakage exceeds maximum allowable.
Demand valve assembly not Tighten demand valve assembly.
tight in regulator case ( (Refer to
IPL FIG. 2), 28 and 28A).
Worn or damaged valve seat Replace valve seat gasket.
gasket ( (Refer to IPL FIG. 2),
24 and 24A; (Refer to IPL FIG.
1B), 840).
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INWARD AND OUTWARD LEAKAGE TESTS
Respirator regulator assembly ( (Refer to Respirator regulator assembly Seal inlet to respirator regulator
IPL FIG. 2), -1 thru -3) leakage exceeds inlet not sealed during testing. assembly.
maximum allowable.
Diaphragm assembly ( (Refer to Replace diaphragm assembly.
IPL FIG. 2), 16; (Refer to IPL
FIG. 1B), 825) punctured or torn.
Respirator regulator assembly ( (Refer to Diaphragm assembly loose or Reinstall diaphragm assembly (
IPL FIG. 2), -1 thru -3) leakage exceeds improperly installed. (Refer to IPL FIG. 2), 16; (Refer
maximum allowable. to IPL FIG. 1B), 825).
Diaphragm cord ( (Refer to IPL Replace diaphragm cord or clamp.
FIG. 2), 17) or clamp (17A) is NOTE: Diaphragm clamp ( (Refer
loose or damaged. to IPL FIG. 2), 17A) replaces cord
(17).
FLOW TEST - DEMAND MODE
Pressure of the demand/pressure- Demand/pressure-demand Set slide button to demand mode.
demand respirator regulator assembly ( respirator regulator ( (Refer to
(Refer to IPL FIG. 2), -2A and -3) is out IPL FIG. 2), 2A and 3) slide
of limits. button (12D) not set to demand
mode.
Worn, binding or damaged Replace demand valve assembly.
demand valve assembly ( (Refer
to IPL FIG. 2), 20; (Refer to IPL
FIG. 1B), 830).
IPL FIG. 2), 16; (Refer to IPL
FIG. 1B), 825) torn or punctured.
Diaphragm assembly ( (Refer to Reinstall diaphragm assembly.
IPL FIG. 2)16; (Refer to IPL FIG.
1B), 825) loose or improperly
installed.
Diaphragm cord ( (Refer to IPL Replace diaphragm cord or clamp.
FIG. 2)17) or clamp (17A) is
loose or damaged.
FLOW TEST - PRESSURE-DEMAND MODE
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Pressure of demand/pressure-demand Demand/Pressure-Demand Set slide button to
respirator regulator assembly ( (Refer to respirator regulator ( (Refer pressure-demand mode.
IPL FIG. 2), -2A and -3) is out of limits. to IPL FIG. 2), -2A and -3)
slide button (12D) not set to
pressure-demand mode.
Worn, binding or damaged Replace demand valve assembly.
demand valve assembly ( (Refer
to IPL FIG. 2), 20; (Refer to IPL
FIG. 1B), 830).
1B), 825) torn or punctured.
Diaphragm assembly ( (Refer to Reinstall diaphragm assembly.
1B), 825) loose or improperly
installed.
Compression spring ( (Refer Adjust or replace compression
to IPL FIG. 2), 12A) out of spring.
adjustment or damaged.
REGULATOR ASSEMBLY OUTPUT PRESSURE TEST
Regulator assembly ( (Refer to IPL FIG. Regulator assembly requires Adjust regulator assembly outlet
7), 1 thru -5) outlet pressure is out of adjustment. pressure.
limits.
Thrust pin ( (Refer to IPL FIG. Replace thrust pin.
7), 50) worn or damaged.
Valve sat assembly ( (Refer to Replace valve seat assembly.
IPL FIG. 7), 49 and 49A; (Refer
to IPL FIG. 1), (Refer to IPL FIG.
1A) and (Refer to IPL FIG. 1B),
795) worn or damaged.
Worn or damaged valve seat Replace body.
area in body ( (Refer to IPL FIG.
7), 55 thru 61).
Diaphragm (46) worn or Replace diaphragm.
damaged.
Diaphragm (46) not sealed in Reposition diaphragm in body.
body (55 thru 61).
Spring (52) or adjusting spring Replace spring or adjusting
(43) damaged. spring.
GAUGE ACCURACY TEST
Gauge ( (Refer to IPL FIG. 9), 1 thru Damaged, obstructed or Replace gauge.
-1D) indicated pressure is out of limits. malfunctioning gauge.
ON-OFF VALVE KIT TORQUE TEST
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Torque required to open and close on/off Threads on head assembly ( Lubricate threads.
valve ( (Refer to IPL FIG. 7), 6 and 6A) (Refer to IPL FIG. 7), 17 and
is out of limits. 17A; (Refer to IPL FIG. 1), (Refer
to IPL FIG. 1A) and (Refer to
IPL FIG. 1B), 800) binding or not
lubricated.
Damaged threads on head Replace head assembly or
assembly ( (Refer to IPL FIG. 7), bushing.
1), (Refer to IPL FIG. 1A) and
(Refer to IPL FIG. 1B), 800) or
bushing ( (Refer to IPL FIG. 7),
19).
Stem assembly ( (Refer to IPL Replace stem assembly.
FIG. 7), 15 and 15A) is bent.
Regulator assembly ( (Refer to IPL FIG. Head assembly ( (Refer to IPL Replace head assembly.
7), 1 thru -5) leaks when on/off valve (6 FIG. 7), 17 and 17A; (Refer to
and 6A) is set to the closed position. IPL FIG. 1), (Refer to IPL FIG.
1A) and (Refer to IPL FIG. 1B),
800) worn or damaged.
Damaged on/off valve seat area Replace body.
in body ( (Refer to IPL FIG. 7),
55 thru 61).
PCA FINAL TEST
Connection leaks between elbow Parts do not have correct seal Disassemble and assemble parts
assembly ( (Refer to IPL FIG. 1B), 15, with thread sealing tape. that leak to the regulator body.
810), outlet assembly ( (Refer to IPL
Threads damaged. Replace damaged part.
FIG. 1B), 300 thru 355; (Refer to IPL
FIG. 3), -1 thru -1K; (Refer to IPL FIG. Part not tight in body. Retighten or retorque part as
4), -1 thru -1J; (Refer to IPL FIG. 5), required.
-1 thru -1G; (Refer to IPL FIG. 6), 1;
(Refer to IPL FIG. 8), -1) relief valve
assembly ( (Refer to IPL FIG. 7), 37),
gauge ( (Refer to IPL FIG. 9), 1 thru
1D), charging valve assembly ( (Refer to
IPL FIG. 7), 23) and body (55 thru 61).
Connection leaks between on/off valve Bushing ( (Refer to IPL FIG. 7), Replace bushing.
( (Refer to IPL FIG. 7), 6 and 6A) and 19) threads damaged.
body (55 thru 61).
Worn, damaged or Replace preformed packing.
non-lubricated preformed
packing ( (Refer to IPL FIG. 7),
1), (Refer to IPL FIG. 1A) and
(Refer to IPL FIG. 1B), 780).
Bushing ( (Refer to IPL FIG. 7), Retorque bushing.
19) not tight in body.
Leakage at relief valve assembly ( (Refer Relief valve assembly Replace relief valve assembly.
to IPL FIG. 7), 37). malfunctioning or damaged.
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Leakage past valve core ( (Refer to Worn or damaged valve core ( Replace charging valve assembly
IPL FIG. 7), 23B) of charging valve (Refer to IPL FIG. 7), 23B) or (23).
assembly (23). body (23).
Valve core (23B) not tight in Replace charging valve assembly
body (23). (23).
Connection between safety outlet Safety plug washer ( (Refer to Replace safety plug washer.
assembly ( (Refer to IPL FIG. 7), 26, 27) IPL FIG. 7), 34; (Refer to IPL
and body (55 thru 61) leaks. FIG. 1), (Refer to IPL FIG. 1A)
and (Refer to IPL FIG. 1B), 770)
damaged.
Leakage past safety outlet assembly ( Safety disc ( (Refer to IPL Replace safety disc or gasket.
(Refer to IPL FIG. 7), 26, 27). FIG. 7), 29, 30) or gasket (32)
damaged.
Safety cap (28) not tight on Retorque safety cap.
safety plug (33).
Connection between packing nut ( Packing nut ( (Refer to IPL FIG. Replace preformed packing.
(Refer to IPL FIG. 7), 13) and bushing 7), 13) does not have correct
(19) leaks. seal using preformed packing
(14, 14A) and PTFE seat (16).
Packing nut (13) not tight in Retorque packing nut.
bushing (19).
Connection between elbow assembly Nut part of connector assembly Tighten nut on tube.
( (Refer to IPL FIG. 1B), 15, 810), ( (Refer to IPL FIG. 1B)10),
connector assembly (10) or tube or tube connector (10A, 815)
connector (10A, 815) and respirator not tight on tube (part of elbow
regulator assembly (30, 35, 45) leaks. assembly).
Worn or damaged ferrule (part Replace connector assembly or
of connector assembly (10) or tube connector. (See NOTE 1).
tube connector (10A, 815).
Connector assembly (10) or tube Disassemble and assemble
connector (10A, 815) does not connector assembly or tube
have correct seal with thread connector to respirator regulator
sealing tape. assembly.
Connector assembly (10) or tube Replace connector assembly or
connector (10A, 815) threads tube connector. (See NOTE 1).
damaged.
Connector assembly (10) or tube Tighten connector assembly or
connector (10A, 815) not tight tube connector.
in respirator regulator assembly
(30, 35, 45).
Leakage past diaphragm ( (Refer to IPL Diaphragm ( (Refer to IPL FIG. Re-install diaphragm avoiding
FIG. 7), 46) 7), 46) wrinkled, due to improper unnecessary wrinkling.
installation.
Diaphragm (46) damaged. Replace and re-install diaphragm.
Table 1008 / Troubleshooting Chart
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Test Data Sheet (Sheet 1 of 3)

Figure 1009/GRAPHIC-35-31-55-999192-095-A01
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Figure 1009/GRAPHIC-35-31-55-999192-095-A01
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Figure 1009/GRAPHIC-35-31-55-999192-095-A01
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DISASSEMBLY
TASK 35-31-55-000-801-A01
1. PORTABLE CYLINDER ASSEMBLY - DISASSEMBLY
A. General
WARNING : STRICTLY OBEY THE PROCEDURES FOR THE USE OF OXYGEN

EQUIPMENT. DO NOT USE OIL, GREASE OR OTHER LUBRICANTS
MADE FROM PETROL IN THE AREA OF OXYGEN EQUIPMENT. THIS
CAN CAUSE A DANGEROUS FIRE HAZARD.
CAUTION : DISASSEMBLE IN A CLEAN WORKSHOP, WITH A GOOD

PROTECTION FROM DUST. KEEP THE WORKBENCH, THE TOOLS
AND THE PARTS CLEAN. USE ONLY THE RECOMMENDED TOOLS
AND THE RECOMMENDED PRODUCTS WHEN YOU DISASSEMBLE.
GIVE A PROTECTION TO THE PARTS AS SOON AS YOU REMOVE
THEM FROM THE EQUIPMENT.
NOTE : Refer to chapter TESTING AND FAULT ISOLATION to find the necessary
level of disassembly. This will give the condition of the equipment and the
most possible cause of the malfunction.
NOTE : Use the IPL to find the part number before you disassemble the equipment.
Refer to the "Effect Code" column (on the Illustrated Parts List) for the parts
applicable to the part number of the equipment that you disassemble. Ignore
the instructions about the parts that are not contained in the equipment
which you disassemble.
NOTE : All item numbers shown in parenthesis ( ) are the same item numbers
used in the IPL.
NOTE : Discard all packings, o-rings and gaskets and replace with new parts.
(a) This section gives step-by-step instructions for a complete disassembly
of a component in a logical sequence and to access any unserviceable
sub-assembly and parts.
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(2) This section describes the equipment and procedures recommended for
disassembling the 807434, 9700, and 9800 Series Portable Cylinder Assemblies
(PCA). Most repair procedures do not need complete disassembly of the PCA.
Disassemble units only to the level necessary to repair or replace components,
Refer to chapter TESTING AND FAULT ISOLATION. Disassembly is organized
as follows:
Paragraph Description IPL Figure No.

2 General PCA Disassembly 1, 1A, 1B, 1C, 7
3 Respirator Regulator Disassembly 1B, 2
4 Regulator Port Device Removal and 1, 1A, 1B, 1C, 3 thru 9
Disassembly
5 General Regulator Assembly and Disassembly 1, 1A, 1B, 1C, 7

(1) Special Tools, Fixtures, and Equipment
to do the maintenance of the component.
NAME QTY PNR SOURCE

Mechanic standard tool kit 1 No specific Local supply
Pneumatic Bench Vise 1 Model BV-101-P PN 58634 Getz Fire Equipment Co.
Peoria, IL 61602-1711
USA (V58013)
Table 3001 / Disassembly - Special Tools, Fixtures and Equipment
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TASK 35-31-55-060-801-A01
2. General PCA Disassembly
WARNING : FAILURE TO FULLY DISCHARGE THE OXYGEN FROM THE PCA OR

COMPONENT PARTS PRIOR TO DISASSEMBLY OF ANY PART, OR
FAILURE TO SECURE THE CYLINDER, REGULATOR ASSEMBLY, AND
DISCHARGE HOSE DURING OXYGEN DISCHARGE MAY CAUSE SERIOUS
PERSONAL INJURY OR DEATH.
High pressure oxygen is a hazardous material. When pressurized oxygen is discharged

intentionally or due to equipment failure, the released energy can be highly destructive if not
properly controlled. Fully discharge the oxygen from the PCA and component parts, prior
to disassembly of any part. Secure the cylinder, regulator assembly, and discharge hose
during oxygen discharge.
WARNING : FAILURE TO USE EYE PROTECTION AT ALL TIMES DURING

DISASSEMBLY PROCEDURES MAY CAUSE INJURY TO THE EYES.
Use eye protection at all times during all disassembly procedures.

Attach a hose equipped with a mating connector ((Refer to Fig. 10) in the DESCRIPTION
AND OPERATION section) to the outlet port equipped with a constant flow or full flow outlet
assembly. Slowly rotate the handle ( (Refer to IPL FIG. 7), 8) of the on/off valve (6, 6A) to
the open (fully counterclockwise) position. Release all the oxygen from the PCA through the
attached hose into a well ventilated area. Rotate the handle of the on/off valve to the closed
(fully clockwise) position and remove the hose from the outlet assembly.
SUBTASK 35-31-55-070-001-A01
A. 9800 Series Only
(1) Unthread the nut on the connector assembly ( (Refer to IPL FIG. 1B), 10) or tube
connector (10A, 815) to allow the connector assembly or tube connector to be
separated from the elbow assembly (15, 810).
NOTE : The nut and compression ferrule (both part of the connector assembly
or tube connector) will be retained on the elbow assembly after the
connector assembly or tube connector and elbow assembly are
separated. Do not attempt to remove the nut or compression ferrule
from the elbow assembly. If the elbow assembly must be replaced, the
elbow assembly and connector assembly or tube connector must be
replaced as a set.
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(2) On the 9800 Series PCA (1 thru -2F), loosen and remove the upper clamp (60
or 120) with the respirator regulator assembly (30 thru 45) attached. Remove
the clamp from the bracket (55). Unthread and discard the self-locking screws
(50) and remove the bracket from the respirator regulator. For PCA (-2F) also
remove the harness (105) from the PCA. Separate the strap assemblies (110,
115) to disassemble the harness (105).
SUBTASK 35-31-55-070-002-A01
B. 807434, 9700, & 9800 Series
(1) Loosen and remove lower clamp ( (Refer to IPL FIG. 1, IPL FIG. 1A, , IPL FIG.
1B, and , IPL FIG. 1C, , 60) from cylinder (, IPL FIG. 1, , 500 thru 500C; , IPL
FIG. 1A, , 505; , IPL FIG. 1B, , 500; IPL FIG. 1C), 505).
(2) On the 9700-A, 9700-B, 9700-C, 9700-D, and 9700-F Series ( (Refer to IPL FIG.
1, 1 thru 1D, 1F thru 1Y, 2C thru 2L); 9700-G, 9700-H Series (, IPL FIG. 1A, , 1
thru 1U); 9800 Series (, IPL FIG. 1B, , 1 thru 2E, 2G, 2K); or 807434-02 (, IPL
FIG. 1C, , 1) PCA remove the harness (, IPL FIG. 1, , IPL FIG. 1A, , IPL FIG. 1B,
and , IPL FIG. 1C, , 100) from the neck of the cylinder (, IPL FIG. 1, , 500 thru
500C; , IPL FIG. 1A, , 505; , IPL FIG. 1B, , 500; IPL FIG. 1C), 505).
NOTE : Although a close fit, the loop-end of the harness is large enough to go
over the regulator assembly ( (Refer to IPL FIG. 7), 1 thru 5B).
(3) Remove the ID plate ( (Refer to IPL FIG. 1, IPL FIG. 1A, , IPL FIG. 1B, and , IPL
FIG. 1C, , 220; , IPL FIG. 1, , 225) from the cylinder (, IPL FIG. 1, , 500 thru 500C;
, IPL FIG. 1A, , 505; , IPL FIG. 1B, , 500; IPL FIG. 1C), 505) only if damaged.
(4) Remove instruction decal ( (Refer to IPL FIG. 1 and , IPL FIG. 1B, , 200; , IPL
FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, , 205) from cylinder (, IPL FIG. 1, ,
500 thru 500C; , IPL FIG. 1A, , 505; , IPL FIG. 1B, , 500; IPL FIG. 1C), 505)
only if damaged.
(5) Remove oxygen ID decal ( (Refer to IPL FIG. 1, IPL FIG. 1A, and , IPL FIG.
1B, , 210, 215; , IPL FIG. 1C, , 215), if equipped, from cylinder (, IPL FIG. 1, ,
500 thru 500C; , IPL FIG. 1A, , 505; , IPL FIG. 1B, , 500; IPL FIG. 1C), 505)
only if damaged.
NOTE : The painted text, “BREATHING OXYGEN ONLY - USE NO OIL”, was
used in place of the oxygen ID decal (( (Refer to IPL FIG. 1 , IPL
FIG. 1A, and IPL FIG. 1B), 210, 215) on some 9700 Series and
9800 Series PCAs.
Page 3004
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-070-003-A01
C. 9700 Series Only
(1) On the 9700 Series PCA ( (Refer to IPL FIG. 1), 2, 2A, 2B), remove harness
assembly with mask and storage bag (125) as follows. Unfasten hook and loop
type fastener strap (145) and remove mask storage bag assembly (140) from
cylinder (500B). Remove the PAX mask assembly (150) from the mask storage
bag assembly. If the PAX mask assembly is in a clear protective bag, cut open
the clear plastic bag and remove the connector (155) from the mask assembly
(150) only if damaged.
NOTE : Refer to AVOX CMM 35-22-26 for more information on the PAX mask
assembly (125).
(2) Loosen and remove the lower clamp (60) and the upper clamp (135) from the
cylinder (500B) and remove the strap assembly (130).
(3) On the 9700 Series PCA (1Z) loosen and remove the upper clamp (120) from the
cylinder. Remove the harness (105) from the PCA. Separate strap assemblies
(110, 115) to disassemble harness (105).
(4) On the 9700 Series PCA (2B) remove the bottle inspection placard (230) from the
cylinder (500B). On the 9700 Series PCA (2A, 2B) remove the instruction placard
(235, 240) from the cylinder (500B).
Page 3005
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-070-004-A01
D. 803668-01 PCA
(1) Loosen and remove the clamp ( (Refer to IPL FIG. 10), 9) from PCA (1).
(2) Remove sling strap (8) from PCA 9700-B1X-BBF25A.
NOTE : Although a close fit, the loop-end of the sling strap is large enough to
go over regulator assembly ( (Refer to IPL FIG. 1), 410A).
(3) Unfasten hook and loop type fastener strap ( (Refer to IPL FIG. 10), 5) and
remove mask storage bag assembly (4) from PCA. Remove plug-in connector (7)
and PAX Mask assemblies (6, 6A) from mask storage bag assembly (4).
(4) Remove oxygen tag (10) from PCA 9700-B1X-BBF25A only if damaged.
(5) Remove instruction decal ( (Refer to IPL FIG. 1), 200, 205) from cylinder (500A)
only if damaged.
(6) Remove oxygen ID decal (210, 215) from cylinder (500A) only if damaged.
NOTE : Painted text “BREATHING OXYGEN ONLY - USE NO OIL”, was used
in place of oxygen ID decal (210, 215) on some cylinders (500A).
(7) (Refer to SUBTASK 35-31-55-070-008-A01) to remove and disassemble gauge (
(Refer to IPL FIG. 7, 35). Remove gauge label ( IPL FIG. 10), 11) from gauge
only if damaged.
(8) Remove outlet identification decal (13, 14) from outlet assembly ( (Refer to IPL
FIG. 1), 255C, 265B) only if damaged.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-060-802-A01
3. Respirator Regulator Assembly Disassembly
Disassemble the respirator regulator as follows.
SUBTASK 35-31-55-070-099-A01
A. Cover Assembly Removal and Disassembly
(1) Unthread pan head screws ( (Refer to IPL FIG. 2), 6, 7) and remove cover
assembly (4, 5) from regulator case (28, 28A).
(2) Remove the rivets (10, 12) and the identification plate (8, 9, 11) from the case
cover (13, 14) only if the identification plate is damaged. Discard the rivets if
removed.
(3) Carefully remove the slide button (12D), spring (12C), compression spring (12A)
and plate w/ lever assembly (12B) from the case cover (13, 14).
NOTE : The plate w/ lever assembly (12B) is not procurable. If a replacement
part is required, a complete cover assembly (5) must be ordered.
SUBTASK 35-31-55-070-005-A01
B. Diaphragm Assembly Removal
(1) Carefully remove the diaphragm cord ( (Refer to IPL FIG. 2, 17) or diaphragm
clamp (17A). Carefully remove the diaphragm assembly (, IPL FIG. 2, , 16; ,
IPL FIG. 1B, , 825) from the regulator case ( IPL FIG. 2), 28, 28A). Discard the
diaphragm cord.
NOTE : The diaphragm cord is not procurable. The diaphragm clamp must be
used to secure diaphragm to the regulator case during assembly.
SUBTASK 35-31-55-070-006-A01
C. Deflector and Demand Valve Assembly Removal and Disassembly
(1) Unthread the pan head screws ( (Refer to IPL FIG. 2, 19, 19A; , IPL FIG. 1B, ,
835) and remove the deflector ( IPL FIG. 2),18) from the regulator case (28, 28A).
(2) Unthread the pan head screws (21, 21A) and remove the lock washer (22, 22A),
flat washer ( (Refer to IPL FIG. 2, 23, 23A; , IPL FIG. 1B, , 820) and demand
valve assembly (, IPL FIG. 2, , 20; , IPL FIG. 1B, , 830) from the regulator case (
IPL FIG. 2), 28, 28A).
(3) Remove and discard the valve seat gasket ( (Refer to IPL FIG. 2, 24, 24A; , IPL
FIG. 1B, , 840) from the regulator case ( IPL FIG. 2), 28, 28A).
Page 3007
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-070-007-A01
D. General Disassembly
(1) Remove the remaining respirator regulator assembly components from regulator
case ( (Refer to IPL FIG. 2), 28, 28A) as follows.
(a) Unthread the connector ( (Refer to IPL FIG. 1B, 10) or tube connector (10A,
815) from the regulator case (, IPL FIG. 2, , 28, 28A). Remove screen (, IPL
FIG. 2, , 27; IPL FIG. 1B), 850) from the regulator case.
(b) Remove the adapter ( (Refer to IPL FIG. 2), 25, 26) from the regulator
case (28, 28A).
(c) Remove the external retaining ring (26C) and cover assembly (26A) from
the adapter body (26B).
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-060-803-A01
4. Regulator Port Device Removal and Disassembly
Unless specified, all removal and disassembly procedures for regulator port devices apply
equally to the 807434, 9700, and 9800 Series PCA. Place the PCA in a Pneumatic Bench
Vise (Refer to Table 3001) for removal of items attached to the regulator ports.
SUBTASK 35-31-55-070-008-A01
A. Gauge
Remove the gauge and disassemble as follows.
CAUTION : ONLY THE LENS, BEZEL, BEZEL WITH LENS, GASKET OR RELIEF
LABEL MAY BE REMOVED FROM THE GAUGE OR DAMAGE MAY
OCCUR.
(1) If damaged, remove and discard the lens ( (Refer to IPL FIG. 9), 10, 10A), bezel
(5, 5A, 7) and bezel with lens (15, 15A) from the gauge (1 thru 1E).
(2) If damaged, remove and discard the relief label (25) or gasket (20) from the
gauge (1D, 1E).
SUBTASK 35-31-55-070-009-A01
B. Relief Valve Assembly
Remove relief valve assembly ( (Refer to IPL FIG. 7), 37) from the body (55 thru 61).
SUBTASK 35-31-55-070-010-A01
C. Charging Valve Assembly
Remove the charging valve assembly and disassemble as follows.
(1) Remove the charging valve assembly ( (Refer to IPL FIG. 7), 23) from the body
(55 thru 61).
(2) Remove the filler cap (21, 21A) from the charging valve (23). The filler cap (21)
and filler cap seat (22) are non-procurable parts. Do not disassemble the filler cap
seat (22) from filler cap (21).
NOTE : If replacement parts for the filler cap (21) or filler cap seat (22) are
required, the filler cap (21A) must be ordered as a replacement part.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-070-011-A01
D. Safety Outlet Assembly
Remove the safety outlet assembly and disassemble as follows.
(1) Remove the safety outlet assembly ( (Refer to IPL FIG. 7), 26, 27) from the body
(55 thru 61).
(2) Remove and discard the safety plug washer ( (Refer to IPL FIG. 7, 34; , IPL
FIG. 1, , IPL FIG. 1A, , IPL FIG. 1B, and , IPL FIG. 1C, , 770) from the body (
IPL FIG. 7), 55 thru 61).
(3) Remove the safety cap (28), safety disc (29, 30) and gasket (32) from the safety
plug (33). Discard the safety disc and gasket.
SUBTASK 35-31-55-070-012-A01
E. On-Off Valve Kit
Remove and disassemble the on/off valve kit as follows.
(1) Remove the on/off valve kit ( (Refer to IPL FIG. 7), 6, 6A) from the body (55
thru 61).
(2) Remove the filter ( (Refer to IPL FIG. 7, 20; , IPL FIG. 1, , IPL FIG. 1A, , IPL FIG.
1B, and , IPL FIG. 1C, , 765) from the body ( IPL FIG. 7), 55 thru 61).
(3) Remove and discard identification plate ( (Refer to IPL FIG. 7, 7; , IPL FIG. 1, ,
IPL FIG. 1A, , IPL FIG. 1B, and , IPL FIG. 1C, , 790) from handle ( IPL FIG. 7), 8).
NOTE : The nut (9, 9A) and washer (10, 10A) are not procurable. The
self-locking hex nut (9C) replaces the nut (9, 9A, 9B) and washer
(10, 10A).
(4) Unthread the self-locking hex nut (9C) and remove handle (8), spring washer (11)
and flat washers (12) from the stem assembly (15, 15A).
(5) Unthread the packing nut (13) from the bushing (19). Remove the preformed
packing ( (Refer to IPL FIG. 7, 14, 14A; , IPL FIG. 1, , IPL FIG. 1A, , IPL FIG. 1B,
and , IPL FIG. 1C, , 775) and seat (, IPL FIG. 7, , 16; , IPL FIG. 1, , IPL FIG. 1A, ,
IPL FIG. 1B, and , IPL FIG. 1C, , 760) from the stem assembly ( IPL FIG. 7), 15,
15A). Discard the preformed packing.
(6) Remove stem assembly (15, 15A) and unthread head assembly ( (Refer to IPL
FIG. 7, 17, 17A; , IPL FIG. 1, , IPL FIG. 1A, , IPL FIG. 1B, and , IPL FIG. 1C, ,
800) from the bushing ( IPL FIG. 7), 19).
(7) Remove and discard the preformed packing ( (Refer to IPL FIG. 7, 18, 18A; , IPL
FIG. 1, , IPL FIG. 1A, , IPL FIG. 1B, and , IPL FIG. 1C, , 780) from the bushing (
IPL FIG. 7), 19).
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-070-013-A01
F. APN 5009-00, 5009 Series Outlet Assembly
Remove the “adjustable” 5009-00 outlet. If the “adjustable” 5009-00 outlet does not
meet the required flow rates (Refer to TASK 35-31-55-700-803-A01), discard it and
replace with a 5009 Series “precision” outlet assembly.
Remove and disassemble the 5009 Series Outlet Assembly as follows.
NOTE : Replacement parts are not available for the outlet subassembly (
(Refer to IPL FIG. 3), 6, 6A), flow port (11), filter (13), retaining ring
(12), gasket (14), stud (7, 7A), glass cord (5), screen (4), screw (3) or
orifice (20). Do not disassemble these parts.
(1) For “precision” outlets, remove the dust cover (2) from the receptacle (15) only
if damaged.
(2) For “precision” outlets, unthread the receptacle (15) from the stud (7, 7A).
(3) For “precision” outlets, remove spring (10), valve (9) and gasket (8) from
receptacle (15). Discard gasket.
SUBTASK 35-31-55-070-014-A01
G. APN 5041-00, 5041 Series Outlet Assembly
replace with a 5041 Series “precision” outlet.
NOTE : Replacement parts are not available for the screw ( (Refer to IPL
FIG. 4), 6), screen (7, 9), glass cord (8), coupling assembly (10),
outlet subassembly (10A), body (12, 12A) or orifice (19). Do not
disassemble these parts.
(1) For “precision” outlets, unthread the nut (3) and remove the cover assembly (2),
cap (4) and washer (5) from the case (18).
(2) For “precision” outlets, remove the springs (16) from the pins (17) and remove
the pins from the case (18).
(3) For “precision” outlets, unthread the setscrew (11) from the case (18).
(4) For “precision” outlets, unthread the case (18) from the body (12, 12A).
(5) For “precision” outlets, remove the spring (13), valve (14) and valve seat (15) from
the case (18). Discard the valve seat.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-070-015-A01
H. APN 5507-00, 5507 Series Outlet Assembly
replace with 5507 Series “precision” outlet.
NOTE : Replacement parts are not available for the screw ( (Refer to IPL FIG.
5), 2), screen (4), glass cord (3), outlet subassembly (5), body (12,
12A) or orifice (13). Do not disassemble these parts.
(1) For “precision” outlets, unthread the fillister head screw (6D) and remove the dust
cover (6C) and torsion spring (6B) from threaded adapter (6A) or guide assembly
(6). Discard fillister head screw.
(2) For “precision” outlets, remove the threaded adapter (6A) or guide assembly (6)
from the body (12, 12A) and remove the lock-washer (7, 7A), retaining washer (8),
outlet washer (8A), seat washer (9), outlet gasket (9A), seat (10), outlet poppet
(10A) and flow-stop spring (11, 11A). Discard the seat washer (9) or gasket (9A).
SUBTASK 35-31-55-070-016-A01
I. APN 10003566 Oxygen Coupling
Remove the oxygen coupling ( (Refer to IPL FIG. 1) and (Refer to IPL FIG. 1B), 335).
NOTE : The oxygen coupling (335) is replaced by the outlet assembly (340).
Do not disassemble oxygen coupling.
SUBTASK 35-31-55-070-017-A01
J. APN 802856-01 Outlet Assembly
NOTE : The outlet assembly ( (Refer to IPL FIG. 1 and IPL FIG. 1B), 340) replaces
the oxygen coupling (335).
(1) Remove the warning label ( (Refer to IPL FIG. 8), 6) and dust cover retainer (2)
from the dust cover (5) only if damaged.
(2) Twist and unlock the dust cover (5) from the groove pin (4) on the disconnect
fitting (3). Remove the dust cover (5).
(3) Remove the preformed packing (12, 13), disconnect body (11), quad ring (10),
disconnect poppet (9), poppet spring (8) preformed packing (7) and gasket (7A)
from the disconnect fitting (3). Discard the quad ring and preformed packing
or gasket.
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35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-070-018-A01
K. APN 5052-00 Outlet Assembly
Remove and disassemble the 5052-00 outlet assembly as follows.
NOTE : The outlet assembly ( (Refer to IPL FIG. 1 and , IPL FIG. 1B, , 320),
and replacement parts (, IPL FIG. 6, , 2 thru 13) are not procurable.
If replacements are required, the outlet assembly must be replaced
by a precision type outlet assembly. Choose a precision type outlet
assembly that is procurable Fig. 4). Disassembly of the 5052-00 outlet
assembly is not recommended.
SUBTASK 35-31-55-070-019-A01
L. APN DPB153 Outlet Assembly
Remove the outlet assembly ( (Refer to IPL FIG. 1), (Refer to IPL FIG. 1A) and (Refer
to IPL FIG. 1B), 350). Do not disassemble.
NOTE : The outlet assembly ( (Refer to IPL FIG. 1 , , IPL FIG. 1A, and IPL FIG.
1B), 350) is not procurable and is replaced by outlet assembly (355).
SUBTASK 35-31-55-070-020-A01
M. APN 36728-01 Outlet Assembly
Remove the outlet assembly ( (Refer to IPL FIG. 1), (Refer to IPL FIG. 1A) and (Refer
to IPL FIG. 1B), 355).
NOTE : Replacement parts are not procurable for this outlet assembly. Do not
disassemble the outlet assembly.
SUBTASK 35-31-55-070-021-A01
N. APN 10008298 Outlet Assembly
Remove the outlet assembly ( (Refer to IPL FIG. 1), 345).
NOTE : Replacement parts are not procurable for this outlet assembly. Do not
disassemble the outlet assembly.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
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35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-060-804-A01
5. General Regulator Disassembly
Place the PCA ( (Refer to IPL FIG. 1), 1 thru 2M; (Refer to IPL FIG. 1A), 1 thru 1V; (Refer
to IPL FIG. 1B), 1 thru 2K and (Refer to IPL FIG. 1C), 1) in a Pneumatic Bench Vise
(Refer to Table 3001) to remove the regulator body ( (Refer to IPL FIG. 1), 400 thru 410A;
(Refer to IPL FIG. 1A), 415 and 420; (Refer to IPL FIG. 1B), 400 thru 405A; (Refer to IPL
FIG. 1C), 415) from the cylinder.
SUBTASK 35-31-55-070-022-A01
A. 807434, 9700, and 9800 Series
(1) Remove the screws ( (Refer to IPL FIG. 7, 39, 39A; , IPL FIG. 1, , , IPL FIG. 1A, ,
, IPL FIG. 1B, and , IPL FIG. 1C, , 805), identification plate (, IPL FIG. 7, , 38; ,
IPL FIG. 1, , , IPL FIG. 1A, , , IPL FIG. 1B, and , IPL FIG. 1C, , 785) and setscrew
( IPL FIG. 7), 40, 40A) from the spring case (41, 41A). Discard screws.
(2) Carefully unthread the spring case (41, 41A) from the body (55 thru 61). Remove
the spring guide (42, 42A), adjusting spring (43), slip ring (45), diaphragm plate
(44), diaphragm (46), and thrust plate (47) from the case (41, 41A).
(3) Unthread the holder (48) and remove the seat assembly ( (Refer to IPL FIG.
7, 49, 49A; , IPL FIG. 1, , , IPL FIG. 1A, , , IPL FIG. 1B, and , IPL FIG. 1C,
, 795), thrust pin ( IPL FIG. 7), 50), thrust pin guide (51) and spring (52) from
the body (55 thru 61).
(4) Remove the drive screws (64) securing the identification plate (63) from the
regulator body (55 thru 61). Discard the drive screws.
(5) Unthread the regulator body (55 thru 61) from the cylinder ( (Refer to IPL FIG. 1,
500 thru 500C; , IPL FIG. 1A, , 505; , IPL FIG. 1B, , 500; IPL FIG. 1C), 505).
SUBTASK 35-31-55-070-023-A01
B. 9700-G2A and 9700-H2A Series Only
On 9700-G2A and 9700-H2A Series PCAs ( (Refer to IPL FIG. 1A), 1 thru 1V), remove
the following items.
(1) Remove the metal boss seal ( (Refer to IPL FIG. 7), 54) from the regulator body
(60, 61). Discard the metal boss seal.
SUBTASK 35-31-55-070-024-A01
C. P/N 807434 Series Only
(1) Remove the preformed packing ( (Refer to IPL FIG. 7), 54B) from the regulator
body (60). Discard the preformed packing.
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Page 3016
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
CLEANING
TASK 35-31-55-100-801-A01
1. PORTABLE CYLINDER ASSEMBLY - CLEANING
A. Job Set-Up Information

(1) General
(a) This section contains information about the equipment and the procedures
for cleaning the 807434, 9700, and 9800 Series PCA. Before cleaning, the
units shall be disassembled, Refer to chapter DISASSEMBLY for procedures.
NOTE : Unless otherwise noted, any use of an item number in this
section includes all alpha variants and dashed variants (i.e.,
items not shown) of that number. For example, item (500)
includes 500, -500, -500A thru -500D, unless otherwise noted.
WARNING : USE EYE PROTECTION AT ALL TIMES DURING

THESE PROCEDURES. IF YOU DO NOT OBEY THESE
INSTRUCTIONS,THERE IS A RISK OF INJURY TO THE EYES.
(b) Use eye protection at all times during all cleaning procedures.
WARNING : REFER TO AND OBEY APPLICABLE MANUFACTURER'S OR

SUPPLIER'S SAFETY DATA SHEET (MSDS) BEFORE YOU
USE CLEANING MATERIALS. IF YOU DO NOT OBEY THESE
INSTRUCTIONS, THERE IS A RISK OF SERIOUS PERSONAL
INJURY, ILLNESS OR DEATH.
(c) Material Safety Data Sheets (MSDS) give information about chemical
makeup and properties of materials that are possibly dangerous to your
health and safety. Refer to the MSDS for storage, disposal, and safety
information.
WARNING : DO NOT USE OXYGEN EQUIPMENT IN AN AREA WITH OIL,

GREASE, FLAMMABLE SOLVENTS OR OTHER FLAMMABLE
MATERIALS SUCH AS DUST, LINT, AND FINE METAL
PARTICLES. USE OXYGEN EQUIPMENT ONLY WITH CLEAN
HANDS, GLOVES AND TOOLS. IF YOU DO NOT OBEY THESE
INSTRUCTIONS, THERE IS A RISK OF SERIOUS PERSONAL
INJURY OR DEATH.
(d) Fire and explosion can occur if oil, grease, flammable solvents, or other
combustible materials cause contamination on oxygen equipment. Materials
that do not usually burn in air, such as dust, lint, and fine metal particles,
can cause fire when oxygen is in use. Carefully use oxygen equipment only
in a clean area and with clean hands, gloves and tools.
Page 4001
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES

to clean the components.
NAME PNR SOURCE

Protective Cap or Plug No specific Local supply
Table 4001 / Cleaning - Special Tools, Fixtures and Equipment
(3) Consumables
(a) (Refer to Table 4002) for the consumables necessary to do the cleaning of
the component.
an alternative.
NAME PNR SOURCE

Non-ionic detergent MIL-D-16791, Type I Local supply
Table 4002 / Cleaning - Consumables
Page 4002
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES


Oxygen System and Component SAE ARP 1176
Cleaning and Packaging
Military Specification MIL-D-16791
Detergents, General Purpose
Liquid, Non-ionic
Standards for Visual Inspection of Steel Compressed C-6
Gas Cylinders
Guidelines for Visual and C-6.2
Requalification of Fiber Reinforced
High Pressure Cylinders
Cleaning Equipment for G-4.1
Oxygen Service
Phosphate Coating, Heavy Manganese or Zinc Base MIL-DTL-16232 (TYPE Z / CLASS 3)
Cylinders, Compressed Gas; High Pressure, Steel RR-C-901C
DOT 3AA and Aluminum Applications, General
Specifications for:
Chemical Conversion Coatings and Pretreatments for TT-C-490 (Cleaning Method I Conversion Coating
Ferrous Surfaces (Base for Organic Coatings) Type V
Table 4003 / Cleaning - Reference Documents
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TASK 35-31-55-100-802-A01
2. Cleaning of the Cylinder
The 807434 Series PCA uses a composite carbon fiber reinforced aluminum cylinder to store
oxygen. The 9700 Series PCA uses either a steel or composite Kevlar® fiber reinforced
aluminum cylinder. The 9800 Series PCA use only steel cylinders. External cleaning and
general internal cleaning procedures are the same for both steel and composite cylinders
used with the PCA.
SUBTASK 35-31-55-140-001-A01
A. External Cleaning
NOTE : See reference CGA G-4.1 in Table 4003.
(1) Seal the opening at the neck of the cylinder using the protective cap (Refer to
Table 4001).
(2) Clean the cylinder.
(3) Rinse the outside of the cylinder with clean water.
(4) Dry the cylinder.
(5) Remove the protective cap from the cylinder opening.
SUBTASK 35-31-55-140-002-A01
B. Internal Cleaning
CAUTION : THE NECK AND THREADED AREA OF COMPOSITE CYLINDERS

MUST NOT BE CLEANED USING ANY ABRASIVE ACTION OR
ABRASIVE MATERIALS, INCLUDING WIRE BRUSHES OR ABRASIVE
PRODUCTS, OR DAMAGE TO SEALING SURFACES OR THREADS
MAY OCCUR.
(1) Refer to CGA pamphlet G-4.1 in Table 4003 for procedures to clean the inside
of composite cylinders.
(2) If corrosion is observed on the internal surface of steel cylinders, forward the
cylinders to a US DOT authorized repair station where the cylinders can be
cleaned and phosphate coated as required, then hydrostatically tested, all
per accepted industry standards G-4.1, MIL-DTL-16232 (TYPE Z/CLASS 3),
RR-C-901C, and TT-C-490 (Cleaning Method I Conversion Coating Type V)(Refer
to Table 4003).
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-160-801-A01
3. Passenger Mask Assemblies
If applicable, refer to the CLEANING section of AVOX Systems CMM 35-22-26 for procedures
on cleaning a passenger mask assembly.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-110-801-A01
4. Metallic Parts
A. Cleaning Information
(1) Refer to ARP 1176 in Table 4003 for cleaning practices for metallic parts.
(2) Make sure that all metallic parts in direct contact with oxygen are cleaned to a
cleanliness level of category 1C per ARP 1176 (Refer to Table 4003).
(3) Do not clean the used drive screws ( (Refer to IPL FIG. 7, 64), metal boss seal
(54), filters (, IPL FIG. 7, , 20; , IPL FIG. 1, and , IPL FIG. 1A, , 765), gasket (, IPL
FIG. 7, , 32), safety disc (29, 30) or identification plate (, IPL FIG. 7, , 38; , IPL
FIG. 1, , , IPL FIG. 1A, , , IPL FIG. 1B, and , IPL FIG. 1C, , 785), rivet ( IPL FIG.
2), 10, 12). These items must be replaced each time they are removed.
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-130-801-A01
5. Non-Metallic Parts
A. Cleaning Information
(1) Refer to ARP 1176 in Table 4003 for cleaning practices for non-metallic parts.
(2) Make sure that all non-metallic parts in direct contact with oxygen are cleaned to
a cleanliness level of category 1C per ARP 1176 (Refer to Table 4003).
(3) Do not clean the diaphragm cord ( (Refer to IPL FIG. 2, 17), valve seat gasket
(, IPL FIG. 2, , 24, 24A; , IPL FIG. 1, , , IPL FIG. 1A, , , IPL FIG. 1B, and , IPL
FIG. 1C, , 840), gasket (, IPL FIG. 3, , 14; , IPL FIG. 5, , 9A; , IPL FIG. 8, , 7A)
preformed packing (, IPL FIG. 7, , 14, 14A, 18, 18A, 54B; , IPL FIG. 1, , IPL FIG.
1A, , IPL FIG. 1B, and , IPL FIG. 1C, , 775, 780), safety plug washer (, IPL FIG.
7, , 34; , IPL FIG. 1, , IPL FIG. 1A, , IPL FIG. 1B, and , IPL FIG. 1C, , 770), quad
ring (, IPL FIG. 8, , 10) or valve seat ( IPL FIG. 4), 15). These items must be
replaced each time they are removed.
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-140-801-A01
6. Miscellaneous Parts
Do not clean the self-locking screws ( (Refer to IPL FIG. 1B), 50; (Refer to IPL FIG. 7), 39,
39A; (Refer to IPL FIG. 1) (Refer to IPL FIG. 1A) (Refer to IPL FIG. 1B) (Refer to IPL FIG.
1C), 805), or fillister head screw ( (Refer to IPL FIG. 5), 6D). These items must be replaced
each time they are removed for disassembly.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Page 4014
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-140-802-A01
7. Optional Cylinder Mounting Bracket Assemblies
For information on the cleaning of optional Mounting Bracket Assemblies APN 36758-11, -12,
-22, refer to AVOX Systems ACMM 35-37-58.
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
INSPECTION/CHECK
TASK 35-31-55-210-801-A01
1. PORTABLE CYLINDER ASSEMBLY - INSPECTION/CHECK
A. General
WARNING : DO NOT USE OXYGEN EQUIPMENT IN AN AREA WITH OIL,

GREASE, FLAMMABLE SOLVENTS OR OTHER FLAMMABLE
MATERIALS SUCH AS DUST, LINT, AND FINE METAL PARTICLES.
USE OXYGEN EQUIPMENT ONLY WITH CLEAN HANDS, GLOVES
AND TOOLS. IF YOU DO NOT OBEY THESE INSTRUCTIONS, THERE
IS A RISK OF SERIOUS PERSONAL INJURY OR DEATH.

(a) After disassembly and cleaning of any component, assembly or unit,
examine each part before assembly. If you are not sure that a part is
serviceable, replace it, Refer to chapter ASSEMBLY.
(2) The instructions in this section apply to all 807434, 9700, and 9800 PCA’s unless
noted otherwise. Refer to the ILLUSTRATED PARTS LIST section of this manual
for the item numbers given in parentheses.
NOTE : Unless otherwise noted, any use of an item number in this section
includes all alpha variants and dashed variants (i.e., items not shown)
of that number. For example, item (500) includes 500, -500, -500A
thru -500D, unless otherwise noted.

to do the inspection of the component.
NAME PNR SOURCE

Inspection light No specific Local supply
Magnifying glass No specific Local supply
Table 5001 / Inspection/Check - Special Tools, Fixtures and Equipment
Page 5001
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES


Methods for Pressure Testing CGA C-1
Cylinder Service Life for Seamless High Pressure CGA C-5
Cylinders
Standards for Visual Inspection of Steel Compressed CGA C-6
Gas Cylinders
Guidelines for Visual and CGA C-6.2
Requalification of Fiber Reinforced
High Pressure Cylinders
Special Permit for Composite Cylinder DOT-SP-8162-1850
Code of Federal Regulations - Part 49 Para 180.209 49 CFR 180.209
(Requirements for Requalification of Specification
Cylinders)
Table 5002 / Inspection/Check - Reference Documents
Page 5002
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-210-802-A01
2. Overhaul (Incorporation of SIL-35-23, SIL-35-25, and SIL-35-117)
SUBTASK 35-31-55-210-001-A01
A. Overhaul Period
(1) (Refer to Table 5004) for overhaul recommendations for PCAs that are subject
to US DOT Regulations. Other requirements may apply in your country (for
example Transport Canada (TC) permits may affect cylinders when offered for
transport or import in or to Canada.
SUBTASK 35-31-55-210-002-A01
B. Minimum Necessary Parts to Replace for an Overhaul
(1) Replace the parts in the Overhaul Kit PN 28022-00 for an overhaul of all 807434
and 9700 Series PCAs. Refer to ( (Refer to IPL FIG. 1, IPL FIG. 1A, and IPL
FIG. 1C), 750 thru 810).
(a) The frangible safety disc (PN 7171-00) for an overhaul of the 9700-A,
9700-B, 9700-C, 9700-D, 9700-F Series and 803668-01 PCA must be
replaced in an overhaul. The frangible safety disc (PN 10003742) for the
overhaul of the 807434, 9700-G2A and 9700-H2A Series PCA must also
be replaced in an overhaul. The frangible safety discs are not included
in the Overhaul Kit.
(b) The gasket (PN 6555-00) for an overhaul of all 807434 and 9700 Series
PCAs must also be replaced in an overhaul. The gasket is not included
in the Overhaul Kit.
(c) You must replace other parts if they are defective.
(2) Replace the parts in the Overhaul Kit PN 28021-00 and the frangible safety disc
(PN 7171-00) for an overhaul of the 9800 Series PCA. (Refer to IPL FIG. 1B),
750 thru 860).
(a) The gasket (PN 6555-00) for an overhaul of the 9800 Series PCA must also
be replaced in an overhaul. The gasket is not included in the Overhaul Kit.
(b) You must replace other parts if they are defective.
SUBTASK 35-31-55-210-003-A01
C. Functional Tests that are Necessary After an Overhaul
(1) You must do all the functional tests in the CMM after you overhaul the 807434
Series, 9700 Series, 9800 Series, or 803668-01 PCA. You must follow all
applicable procedures in this CMM when you do an overhaul.
Page 5003
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-210-004-A01
D. Overhaul of a PCA
(1) During an overhaul of a PCA, the following items may require replacement due to
damage during disassembly or from rough handling.
Identification Plate ( (Refer to IPL FIG. 1), (Refer to IPL FIG. 1A), (Refer to IPL
FIG. 1B) and (Refer to IPL FIG. 1C), 220; (Refer to IPL FIG. 1), 225; (Refer to IPL
FIG. 2), 8, 9; (Refer to IPL FIG. 7), 62, 63).
Instruction Decal ( (Refer to IPL FIG. 1) and (Refer to IPL FIG. 1B), 200; (Refer to
IPL FIG. 1), (Refer to IPL FIG. 1A) and (Refer to IPL FIG. 1B), 205).
Oxygen Identification Decal ( (Refer to IPL FIG. 1), (Refer to IPL FIG. 1A) and
(Refer to IPL FIG. 1B), 210, 215; (Refer to IPL FIG. 1C), 215).
Bottle Inspection Placard ( (Refer to IPL FIG. 1), 230).
Operating Instructions Placard ( (Refer to IPL FIG. 1), 235, 240).
Oxygen Tag ( (Refer to IPL FIG. 10), 10).
(2) When removed or disassembled, the following items must be discarded and
replaced with new parts.
Safety Disc ( (Refer to IPL FIG. 7), 29, 30).
Gasket ( (Refer to IPL FIG. 3), 8; (Refer to IPL FIG. 5), 9A; (Refer to IPL FIG. 7),
32; (Refer to IPL FIG. 8), 7A).
Identification Plate ( (Refer to IPL FIG. 7), 7; (Refer to IPL FIG. 1), (Refer to IPL
FIG. 1A) and (Refer to IPL FIG. 1B), 790).
Self-locking hex nut ( (Refer to IPL FIG. 7), 9C).
Preformed Packing ( (Refer to IPL FIG. 7), 14, 14A, 18, 18A; (Refer to IPL FIG.
8), 7, 12, 13; (Refer to IPL FIG. 1), (Refer to IPL FIG. 1A) and (Refer to IPL
FIG. 1B), 775, 780).
Diaphragm Cord ( (Refer to IPL FIG. 2), 17)
Valve Seat Gasket ( (Refer to IPL FIG. 2), 24, 24A; (Refer to IPL FIG. 1), (Refer
to IPL FIG. 1A) and (Refer to IPL FIG. 1B), 840).
Safety Plug Washer ( (Refer to IPL FIG. 7), 34; (Refer to IPL FIG. 1), (Refer to
IPL FIG. 1A) and (Refer to IPL FIG. 1B), 770).
Seat Washer ( (Refer to IPL FIG. 5), 9).
Quad Ring ( (Refer to IPL FIG. 8), 10).
Self-Locking Screw ( (Refer to IPL FIG. 7), 39, 39A; (Refer to IPL FIG. 1), (Refer
to IPL FIG. 1A) and (Refer to IPL FIG. 1B), 805).
Valve Seat ( (Refer to IPL FIG. 4), 15).
Rivet ( (Refer to IPL FIG. 2), 10, 12).
Fillister Head Screw ( (Refer to IPL FIG. 5), 6D).
Drive Screw ( (Refer to IPL FIG. 7), 64).
Metal Boss Seal ( (Refer to IPL FIG. 7), 54).
Preformed Packing ( (Refer to IPL FIG. 7), 54B).
Locking Oval Point Setscrew ( (Refer to IPL FIG. 7), 40A; (Refer to IPL FIG. 1)
and (Refer to IPL FIG. 1A), -810 (Refer to IPL FIG. 1B), -855).
Pan Head Screw ( (Refer to IPL FIG. 2), 21A; (Refer to IPL FIG. 1B), -860).
Page 5004
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-210-005-A01
E. Items to be replaced with new parts
(1) When removed or disassembled, the following items should be discarded and
replaced with new parts. These items are attached by adhesive, and should
not be reused. Reuse of these items may cause them to detach from the PCA,
creating potential for “foreign object damage”.
Identification Plate ( (Refer to IPL FIG. 1), (Refer to IPL FIG. 1A), (Refer to IPL
FIG. 1B) and (Refer to IPL FIG. 1C), 220; (Refer to IPL FIG. 1), 225; (Refer to
IPL FIG. 2), 15; (Refer to IPL FIG. 7), 7; (Refer to IPL FIG. 1), (Refer to IPL FIG.
1A) and (Refer to IPL FIG. 1B), 790).
Instruction Decal ( (Refer to IPL FIG. 1) and (Refer to IPL FIG. 1B), 200; (Refer to
IPL FIG. 1), (Refer to IPL FIG. 1A) and (Refer to IPL FIG. 1B), 205)
Oxygen Identification Decal ( (Refer to IPL FIG. 1), (Refer to IPL FIG. 1A) and
(Refer to IPL FIG. 1B), 210, 215; (Refer to IPL FIG. 1C), 215).
Bottle Inspection Placard ( (Refer to IPL FIG. 1), 230).
Operating Instructions Placard ( (Refer to IPL FIG. 1), 235, 240).
Warning Label ( (Refer to IPL FIG. 8), 6).
Relief Label ( (Refer to IPL FIG. 9), 25).
Oxygen Tag ( (Refer to IPL FIG. 10),10).
Outlet Identification Decal ( (Refer to IPL FIG. 10), 13, 14).
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Page 5006
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-210-802-A01
3. Service Flow Check (Incorporation of SB 9700-35-01 and SB 9800-35-01)
SUBTASK 35-31-55-210-013-A01
A. Affected PCAs with Serial Numbers
(1) A quantity of PCAs shipped from AVOX systems have an incorrectly set outlet
flow level due to the use of an incorrectly calibrated flow meter in production.
(Refer to Table 5003) for the PCAs that are affected.
PN SNs
9700-A1A-BF23A P12011371 and P12011371
9700-C1A-BF23A P12011447 thru P12011471
9700-C1A-BF23A P12011666 thru P12011670
9800-1D1A-F23AN P12020123
Table 5003 / Affected PCAs
(2) Make sure that the PCAs affected, (Refer to Table 5003), have an “A” on the
regulator identification plate, (Refer to Fig. 5001).
Page 5007
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Re-Identification of the PCA (example)

Figure 5001/GRAPHIC-35-31-55-991-600-A01
(3) If the affected PCAs, (Refer to Table 5003), do not have an “A” on the regulator
identification plate then re-test and stamp the PCAs. Refer to chapter TESTING
AND FAULT ISOLATION.
Page 5008
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-210-803-A01
4. PCA and PCA Components
SUBTASK 35-31-55-210-006-A01
A. General
(1) Do a check of the surfaces and thread areas for signs of damage, contamination,
galling, burrs, corrosion or too much wear.
CAUTION : PCA MAY BE DAMAGED OR LEAK IF A PART THAT EITHER HAS,

OR HAS CAUSED TOO MUCH WEAR OR DAMAGE TO ADJACENT
SEALING SURFACES IS NOT REPLACED.
(2) Do a check of the mating parts and sealing surfaces for scratches and other
damage that will cause leakage.
SUBTASK 35-31-55-210-007-A01
B. Gauge
(1) Do a check of the gauge ( (Refer to IPL FIG. 7, 35, 36, 36A) for damage to the
gauge case, lens ( IPL FIG. 9), 10, 10A), bezel (5, 5A), lens w/ bezel (15,15A),
bezel (7) or pressure indicating pointer.
SUBTASK 35-31-55-210-008-A01
C. Plates, Decals, Placards and Labels
(1) Make sure that all identification plates ( (Refer to IPL FIG. 1, IPL FIG. 1A, , IPL
FIG. 1B, , IPL FIG. 1C, , 220; , IPL FIG. 1, , 225; , IPL FIG. 2, , 15; , IPL FIG. 7, ,
7; , IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, , 790), instruction decals (, IPL
FIG. 1, and , IPL FIG. 1B, , 200; , IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, ,
205), oxygen identification decals (, IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, ,
200, 215; , IPL FIG. 1C, , 215), warning label (, IPL FIG. 8, , 6) and relief label (
IPL FIG. 9), 25) can be read and are not damaged.
SUBTASK 35-31-55-210-009-A01
D. Harness Assemblies
(1) Make sure that all harness assemblies ( (Refer to IPL FIG. 1, IPL FIG. 1A, ,
IPL FIG. 1B, and , IPL FIG. 1C, , 100; , IPL FIG. 1, and , IPL FIG. 1B, , 105)
and strap assemblies (, IPL FIG. 1, and IPL FIG. 1B), 110, 115) are not cut,
worn or damaged.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-210-010-A01
E. Harness Assemblies with Passenger Mask and Storage Bag
(1) Make sure that all Harness Assemblies with mask and storage bag ( (Refer to IPL
FIG. 1, 110; , IPL FIG. 10, , 3) including Passenger Oxygen Mask Assemblies (,
IPL FIG. 1, , 150; , IPL FIG. 10, , 6, 6A), mask storage bag assemblies (, IPL
FIG. 1, , 140; , IPL FIG. 10, , 4), hook and loop fasteners (, IPL FIG. 1, , 145; ,
IPL FIG. 10, , 5), strap assembly, (, IPL FIG. 1, , 130) and sling strap ( IPL FIG.
10), 8) are not cut, worn, or damaged.
Page 5010
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-210-804-A01
5. Cylinder
(Refer to Table 5004) for information about cylinder hydrostatic testing and cylinder service-life
requirements.
Cylinder inspection frequency or service life information (Refer to Table 5004) is valid for
the date of issue for this 807434 Series, 9700 Series, and 9800 Series PCA Component
Maintenance Manual.
CYLINDER HYDROSTATIC
SERVICE LIFE TESTING
ITEM No.
CYLINDER TYPE (NOTE 1 and PERIOD
(IPL FIG. No)
NOTE 2) (NOTE 1)
Years Years
Composite DOT-SP-8162-1850 505, (IPL Fig. 1A) 15 (Refer to Note 4)
Composite DOT-SP-10915-1850 505 (IPL Fig. 1C) 15 5 (Refer to Note 5.)
Steel DOT-3AA-1800 500 thru 500C (IPL Fig. 1) Unlimited Lifetime 5 or 10 (Refer to
500, (IPL Fig. 1B) (Note 3) 49 CFR 180.209
for applicability.)
NOTE 1: Specific information contained in these columns is taken directly from documents listed in Table 5002.
NOTE 2: Cylinder service-life begins at the initial hydrostatic test date of the cylinder.
NOTE 3: Unlimited lifetime on condition that the cylinder does not fail any remaining inspection or hydrostatic
test requirements.
NOTE 4: US DOT Exemption E 8162 has been superseded by US DOT SP 8162 dated May 11, 2007. US DOT
SP 8162 applies to all units manufactured after September 30, 2007 and changes the hydrostatic test interval of
the composite cylinders used on the 9700 Series PCAs when offered for transport or import in or to the United
States as follows:
When subject to United States DOT regulations:
Cylinders retested prior to July1, 2006 must be inspected and hydrostatically tested within three (3) years of the
retest date marked on the cylinder. AVOX recommends that the regulator be overhauled every six (6) years.
Cylinders retested after July1, 2006 must be inspected and hydrostatically tested within five (5) years of the
retest date marked on the cylinder. AVOX recommends that the regulator be overhauled every five (5) years.
NOTE 5: When cylinders have a five (5) year hydrostatic retest interval, AVOX recommends that the regulator
be overhauled at the time of hydrostatic testing.
Table 5004 / Cylinder Inspection and Regulator Overhaul Frequency
Determine actual cylinder condition (e.g., serviceable, rejected, repairable or condemned) by

using the applicable references from Table 5002. All cylinder repairs must be made before a
hydrostatic test of the cylinder is performed. Any cylinder that has been repaired (as required
in the references in Table 5002) needs a hydrostatic test before it is available for use.
Check composite cylinder or steel cylinder (Refer to Table 5004). Any cylinder that fails the
hydrostatic test must not be used (i.e., condemned).
Page 5011
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-210-011-A01
A. DOT-SP-8162-1850 Composite Cylinder and DOT-SP-10915-1850 Composite Cylinder
(1) Look at the date of the last hydrostatic test of the cylinder. Hydrostatic test dates
will be shown on the cylinder neck or on a hydrostatic retest label. The cylinder
may have more than one hydrostatic retest label. The initial cylinder test date
and US DOT exemption certificate number are shown on the manufacturer’s
identification plate found on the cylinder sidewall.
(2) Hydrostatic tests must be performed as noted in Table 5004 using approved
procedures by service locations having up-to-date United States Department of
Transportation approval. Additional hydrostatic tests may be required in your
country.
(3) (Refer to Table 5004) for the composite cylinder service-life.
(4) Do a check of the exterior of cylinders for twists or bends, cuts, lifting, peeling,
or delamination of the fiber over-wrap, either heat or fire damage, contamination
or other damage.
(5) Make sure that identification plates and warning labels can be read and are not
damaged.
(6) Do a check of the cylinder neck for cracks and distortion. Also check the cylinder
threads for damage and contamination.
NOTE : Make sure that the sealing surface between the regulator assembly
and the cylinder does not have nicks, cuts or distortion. Leakage
will occur between the regulator assembly and cylinder if this surface
is distorted or damaged.
(7) Put a Bright Inspection Light (Refer to Table 5001) inside the cylinder and do a
check for contamination and corroded surfaces.
(8) Make sure the inside of the cylinder does not have an odor.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-210-012-A01
B. DOT-3AA-1800 Steel Cylinder
(1) Look at the last and initial cylinder hydrostatic test dates found on the cylinder
crown, near the cylinder neck.
NOTE : Hydrostatic tests must be performed as noted in Table 5004 using
approved procedures by service locations having up-to-date United
States Department of Transportation approval. Additional hydrostatic
tests may be required in your country.
(2) (Refer to Table 5004) for the DOT-3AA-1800 steel cylinder service-life.
(3) Do a check of the cylinder surfaces for either heat or fire damage.
(4) Do a check of the cylinder for dents, gouges, digs or bulges.
NOTE : It may be necessary to remove any heavy paint coatings from the
exterior surface of the cylinder to correctly check for dents, gouges,
digs or bulges.
(5) Make sure that identification plates and warning labels can be read and are not
damaged.
(6) Do a check of the cylinder neck for cracks, distortion, contamination or thread
damage.
(7) Put a Bright Inspection Light (Refer to Table 5001) inside the cylinder and do a
check for contamination and corroded surfaces.
(8) Make sure the inside of the cylinder does not have an odor.
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Page 5014
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-210-805-A01
6. Optional PCA Mounting Bracket Set
For check information for optional Mounting Bracket Assemblies APN 36758-11, -12, -22,
refer to AVOX Systems ACMM 35-37-58.
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Page 5016
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
REPAIR
TASK 35-31-55-300-801-A01
1. PORTABLE CYLINDER ASSEMBLY – REPAIR
A. General

SYSTEM. YOU CAN CAUSE A FIRE OR EXPLOSION.
(1) Discard all defective components and replace with new ones.
(2) This section gives the repair procedures that can be performed on the 807434,
9700, and 9800 Series PCA. Before repair, examine the components, Refer to
chapter INSPECTION/CHECK.
(3) Do not repair filters, safety discs, gaskets, preformed packings, diaphragm cords,
safety plug washers, seat washers, quad rings, seats, drive screws, metal boss
seals or rivets. These items must be replaced each time they are removed during
disassembly.
NOTE : Self-locking screws (50, IPL Fig. 1B; 39A, IPL Fig. 7; 805, IPL Figs.
1, 1A, 1B) and fillister head screws (6D, IPL Fig. 5) contain a one-time
use (non-replaceable) plastic insert. These items must be replaced
each time they are removed during disassembly.
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to do the maintenance of the component.
NAME PNR SOURCE

Mechanic standard tool No specific Local supply
kit
Inspection light No specific Local supply
Spray Gun Model 19 Binks Manufacturing Company
AMF Ohare, IL 60666-2887
USA (V07334)
Cylinder Hanger (Steel 0.500 in. - 14 ANPT Threads Local supply

Cylinders) Square Drive Plastic Plug Fitting
Cross-Drilled for "S" Hanger
Cylinder Hanger 0.750 - 16UNF-2A Threads Local supply
(Composite Cylinders) Square Drive Plastic Plug Fitting
Cross-Drilled for "S" Hanger
Table 6001 / Repair - Special Tools, Fixtures and Equipment
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(2) Consumables
(a) (Refer to Table 6002) for the consumables necessary to do the maintenance
of the component.
an alternative.
NAME PNR SOURCE

Sandpaper No specific Local supply
320 Grit or Finer
Catalyst R6120 A.P. Nonweiler Co.
Oshkosh, WI
54903-1007
USA
Primer (2 part catalyzed urethane) Light 4285A093 A.P. Nonweiler Co.

Gray Oshkosh, WI
(No. 36628 per FED-STD-595) 54903-1007
USA
Paint (2 part catalyzed urethane) 4285A073 A.P. Nonweiler Co.
Green (No. 24062 per FED-STD-595) 4285K123 Oshkosh, WI
Green (No. 14187 per FED-STD-595) 54903-1007
USA
Paint, Green A2008-14090 Cardinal Industrial
Lacquer Aerosol Spray Can, 12 Oz. Finishes
(No. 14090 Per Fed-Std-595) S. Elmonte, CA 91733
USA
Table 6002 / Repair - Consumables


Colors Used in Government Procurement FED STD-595
Table 6003 / Repair - Reference Documents
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TASK 35-31-55-300-802-A01
2. Repair
Limit repairs to the procedures given below.
A. Refer to chapter CLEANING to clean the unit,
B. Removal of sharp edges.
C. Thread repair.
D. Replacement of cracked, bent, broken, scratched, or otherwise damaged components.
E. Steel cylinder paint application (Refer to TASK 35-31-55-380-801-A01).
F. Composite cylinder paint application (Refer to TASK 35-31-55-380-802-A01).
G. Repair of optional PCA mounting bracket assemblies (Refer to TASK
35-31-55-300-803-A01).
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TASK 35-31-55-380-801-A01
3. Steel Cylinder Paint Application
WARNING : FAILURE TO REFER TO AND FOLLOW THE MANUFACTURER'S OR

SUPPLIER'S MATERIAL SAFETY DATA SHEETS (MSDS) FOR PRIMER,
PAINT OR CATALYSTS FOR MORE PRECAUTIONARY DATA, APPROVED
SAFETY EQUIPMENT AND EMERGENCY MEDICAL AID MAY CAUSE
SERIOUS PERSONAL INJURY OR DEATH.
Paint must only be applied to the exterior surface of the cylinder and may consist of either
small spot repairs or full repainting.
Hydrostatic test marks must remain visible and readable after the paint application.
SUBTASK 35-31-55-350-001-A01
A. Surface Preparation
(1) Steel cylinders ( (Refer to IPL FIG. 1, 500 thru 500C; IPL FIG. 1B), 500) requiring a
complete repainting process should be phosphate coated before paint application.
(2) Steel cylinders requiring a spot repainting process should be lightly sanded with
320 Grit or finer sandpaper (Refer to Table 6002) only enough to roughen the
surface without abrading through the existing paint layer.
(3) (Refer to TASK 35-31-55-100-802-A01) and clean the exterior surface of the
cylinder to remove any contamination.
(4) Remove the cylinder assembly identification plate ( (Refer to IPL FIG. 1 and , IPL
FIG. 1B, , 220; , IPL FIG. 1, , 225), instruction decal (, IPL FIG. 1, and , IPL FIG.
1B, , 200, 205), oxygen identification decal (, IPL FIG. 1, and , IPL FIG. 1B, , 210,
215), operating instruction placard (, IPL FIG. 1, , 235, 240), bottle inspection
placard (, IPL FIG. 1, , 230), and oxygen tag ( IPL FIG. 10), 10), or install masking
tape over these items to protect them from the primer and paint over spray.
SUBTASK 35-31-55-380-002-A01
B. Primer Application
(1) Thread the Cylinder Hanger (0.500 in. - 14 ANPT Threads, (Refer to Table 6001))
into the cylinder.
(2) Mix the Light Gray Primer (Refer to Table 6002) and Catalyst (Refer to Table
6002) using the instructions supplied by the manufacturer.
(3) Filter and spray the catalyzed primer on the cylinder surface with a Spray Gun
using the instructions supplied by the manufacturer.
(4) Allow the cylinder to air dry 15 - 20 minutes before the application of the paint.
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SUBTASK 35-31-55-380-003-A01
C. Paint Application
(1) Thread the Cylinder Hanger (Refer to Table 6001) into the cylinder.
(2) Mix the Paint (No. 24062, (Refer to Table 6002)) and Catalyst (Refer to Table
6002) using the instructions supplied by the manufacturer.
(3) Filter and spray the catalyzed paint onto the cylinder surface with a Spray Gun
using instructions supplied by the manufacturer.
(4) Air-dry cylinder for 60 - 90 minutes at approximately 70°F (21°C) or 25 - 30
minutes at 100 - 150°F (38 - 66°C).
(5) Allow the paint to cool and stabilize for 24 hours before placing the cylinder into
service.
Cylinder assembly identification plate ( (Refer to IPL FIG. 1) and (Refer to IPL FIG. 1B),
220; (Refer to IPL FIG. 1), 225), instruction decal ( (Refer to IPL FIG. 1) and (Refer to
IPL FIG. 1B), 200, 205), oxygen identification decal ( (Refer to IPL FIG. 1) and (Refer to
IPL FIG. 1B), 210, 215), operating instruction placard ( (Refer to IPL FIG. 1), 235, 240),
bottle inspection placard ( (Refer to IPL FIG. 1), 230) and oxygen tag ( (Refer to IPL FIG.
10), 10) removed from cylinder before the paint application process must be replaced.
Refer to the ASSEMBLY section for the proper location and application of these items.
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TASK 35-31-55-380-802-A01
4. Composite Cylinder Paint Application
Paint must be applied only to the exterior surface of the cylinder and may consist of either
small spot repairs or full repainting.
The hydrostatic retest labels and permanently affixed cylinder manufacturer's identification
label must remain visible and readable after the paint application.
SUBTASK 35-31-55-350-002-A01
A. Surface Preparation
CAUTION : THE COMPOSITE CYLINDER OVER-WRAP OR REINFORCING

FIBERS, MUST NOT BE ABRADED DURING THE PRE-PAINTING
PREPARATION OR PERMANENT CYLINDER DAMAGE MAY RESULT.
(1) Composite cylinders ( (Refer to IPL FIG. 1A and IPL FIG. 1C), 505) that require
spot repair or full repainting should be lightly sanded with 320 Grit or finer
sandpaper (Refer to Table 6002) only enough to roughen the surface without
abrading through the existing paint layer.
(2) (Refer to TASK 35-31-55-100-802-A01) and clean the exterior surface of the
cylinder to remove contamination.
(3) Remove the identification plate ( (Refer to IPL FIG. 1A and , IPL FIG. 1C, , 220),
instruction decal (, IPL FIG. 1A, , 205), oxygen identification decal (, IPL FIG. 1A, ,
210, 215; , IPL FIG. 1C, , 215), and oxygen warning decal (, IPL FIG. 1A, and IPL
FIG. 1C), 245) from the cylinder, or install masking tape over them to protect from
paint over spray. Do not remove any hydrostatic retest labels from the cylinder.
Hydrostatic retest labels and the cylinder manufacturer’s identification label on
composite cylinders must be covered with masking tape before painting.
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SUBTASK 35-31-55-380-004-A01
B. Paint Application
(1) Thread the Cylinder Hanger (0.750 - 16 UNF-2A Threads, Table 6001) into the
cylinder.
(2) Mix the Green Paint (No. 14187, (Refer to Table 6002)) and Catalyst (Refer to
Table 6002) using the instructions supplied by the manufacturer.
(3) Filter and spray the catalyzed paint on the cylinder surface ( (Refer to IPL FIG.
1A), 505) with a Spray Gun (Refer to Table 6001) using the instructions supplied
by the manufacturer.
(4) Apply green touch-up paint (No. 14090, (Refer to Table 6002)) to cylinder (
(Refer to IPL FIG. 1C), 505) as needed, using the instructions provided by the
manufacturer.
(5) Dry the cylinder for 60 - 90 minutes at approximately 70°F (21°C) or 25 - 30
minutes at 100 - 125°F (38 - 52°C) in air.
(6) Allow the paint to cool and stabilize for 24 hours before placing the cylinder into
service.
The identification plate ( (Refer to IPL FIG. 1A) and (Refer to IPL FIG. 1C), 220),
instruction decal ( (Refer to IPL FIG. 1A), 205), oxygen identification decal ( (Refer to
IPL FIG. 1A), 210, 215; (Refer to IPL FIG. 1C), 215), and oxygen warning decal ( (Refer
to IPL FIG. 1A) and (Refer to IPL FIG. 1C), 245) that were removed from the cylinder
before the paint application process must be replaced. Refer to the ASSEMBLY section
for the proper location and application of these items.
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TASK 35-31-55-300-803-A01
5. Optional PCA Mounting Bracket Set
A. For repair information for optional Mounting Bracket Assemblies APN 36758-11, -12,
-22, refer to AVOX Systems ACMM 35-37-58.
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ASSEMBLY
TASK 35-31-55-400-801-A01
1. PORTABLE CYLINDER ASSEMBLY - ASSEMBLY
A. General
WARNING : DO NOT USE OIL, GREASE OR OTHER LUBRICANTS MADE FROM

PETROL IN THE AREA OF OXYGEN EQUIPMENT. IF YOU DO NOT
OBEY THESE INSTRUCTIONS, THERE IS A RISK OF SERIOUS
PERSONAL INJURY OR DEATH.
CAUTION : ASSEMBLE PARTS IN A CLEAN WORKSHOP WITH CLEAN TOOLS.

USE ONLY THE RECOMMENDED TOOLS AND MATERIALS. IF YOU
DO NOT OBEY THESE INSTRUCTIONS, DAMAGE TO COMPONENTS
CAN OCCUR.
NOTE : Make sure that cleaning, check and repair of parts have been done before
you assemble.
NOTE : All item numbers shown in parenthesis ( ) are the same item numbers as
used in the IPL.
NOTE : After assembly, do the tests as specified in section TESTING AND FAULT
ISOLATION.
(1) Reason for the job
(a) This section gives step-by step instructions for complete assembly of the
component in a logical sequence.
(b) Assembly is organized as follows.
Paragraph Description IPL No.

3. Outlet Assemblies 3, 4, 5, 6, 8
4. Respirator Regulator Assembly 2
5. Regulator Assembly 7
6. PCA Assembly 1, 1A, 1B , 1C
7. PCA Charging Procedure 1, 1A, 1B, 1C
8. Final PCA Assembly 1, 1A, 1B, 1C
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WARNING : CONTAMINATION OF OXYGEN EQUIPMENT BY FAILING TO

HANDLE OXYGEN EQUIPMENT IN AN AREA CLEAN OF OIL,
GREASE, FLAMMABLE SOLVENTS, OR OTHER COMBUSTIBLE
MATERIALS INCLUDING DUST, LINT, AND FINE METAL PARTICLES;
CONTAMINATION FROM FAILING TO USE CLEAN HANDS, GLOVES,
TOOLS; OR CONTAMINATION BY ANY OTHER MEANS, WHEN
HANDLING OXYGEN EQUIPMENT, MAY RESULT IN FIRE OR
EXPLOSION THAT MAY CAUSE SERIOUS PERSONAL INJURY OR
DEATH.
(2) If oxygen equipment becomes contaminated with oil, grease, flammable solvents,
or other combustible materials, fire and explosion may occur. Also, many
substances and materials that do not normally burn in air, including dust, lint,
and fine metal particles can ignite in the presence of oxygen. Handle oxygen
equipment only in a clean area and with clean hands, gloves, and tools.
WARNING : FAILURE TO USE ONLY OXYGEN COMPATIBLE PRODUCTS,

EQUIPMENT, AND MATERIALS CAN BRING ABOUT A VIOLENT
REACTION RESULTING IN FIRE OR EXPLOSION THAT MAY CAUSE
(3) Many commonly used materials may react violently in the presence of high
pressure oxygen. Only equipment and materials known to be compatible with
oxygen should be used. Do not substitute other equipment or materials such as
elastomeric o-rings, gaskets, seals, and metal components, even if they look
the same.

ASSEMBLY PROCEDURES MAY CAUSE INJURY TO THE EYES.
(4) Use eye protection at all times during all assembly procedures.
The instructions in this section apply to all 807434, 9700, and 9800 PCAs unless
noted otherwise. Refer to the ILLUSTRATED PARTS LIST section of this manual for
the item numbers given in parentheses.
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AVOX SYSTEMS INC.
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to do the maintenance of the components.
NAME QTY PNR SOURCE

Pneumatic Bench Vise 1 Model BV-101-P PN 58634 Getz Fire Equipment Co.
Peoria, IL 61602-1711
USA (V58013)
Refill Coupling 1 5020-01 Avox Systems (53655)
CGA 540 x 0.563-18UNF-
2B Threads
Test Regulator 1 44-1110 Series Tescom Corp.
0 - 2500 psig (0 – 17.2 44-1114 -24 Elk River, MN 55330-2491
MPa) Outlet Pressure USA (V5H642)
Pressure Gauge (minimum 1 1404 Series Ametek Inc. (US Gauge Division)
accuracy ±0.25% full Sellersville, PA 18960-2625
scale) USA (V61349)
0 - 2000 psig (0 – 13.8
MPa)
Table 7001 / Assembly - Special Tools, Fixtures and Equipment
Page 7003
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(2) Consumables
(a) (Refer to Table 7002) for the consumables necessary to do the maintenance
of the components.
NOTE : For oxygen lubricant, it is not permitted to use equivalent
materials. Other consumables that you find to be equivalent
can be used as an alternative.
NAME PNR SOURCE

Thread Sealing Tape PTFE Ribbon Tape CID A-A-58092 Local supply
0.250 in. (0.535 cm)
wide
Leak Detection MIL-PRF-25567, Type I Local supply
Compound, Oxygen
Systems
Red and Green Etching PN S-1141 Marking Device Manufacturing
Ink Co.
Philadelphia, PA 19133-2891
USA (V26040)
Lockwire MS20995C20 Local supply
Oxygen 1850 psig MIL-PRF-27210, Type I Or AS8010, Type I Local supply
(12.76 MPa) MIN
PRESS
Primer No specific Loctite Corp.
Grade T Rocky Hill, CT 06067-3582
USA (V05972)
Adhesive No specific Loctite Corp.
Grade 222 Rocky Hill, CT 06067-3582
USA (V05972)
Sealing Compound No specific Loctite Corp.
Grade 242 Rocky Hill, CT 06067-3582
USA (V05972)
Grease, Aircraft and MIL-PRF-27617, Type I Local supply
Instrument, Fuel and
Oxidizer Resistant
AMS-M-7866 Molybdenum Disulfide, Technical, Lubrication Grade Local supply
Table 7002 / Assembly - Consumables
Page 7004
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES


Transfilling of Industrial and Medical Non-Flammable CGA P-15
Oxygen Cylinder Quality AIR1059
Serviceability, Maintenance Transfilling
and Marking
Aviators Breathing Oxygen Purity Standard AS8010
Molybdenum Disulfide, AMS 7866

Technical,
Lubrication Grade
Commercial Item Description Tape Antiseize, CID A-A-58092
Polytetrafluoroethylene
Grease, Aircraft and Instrument, Fuel and Oxidizer MIL-PRF-27617
Resistant
Military Specification Oxygen, Aviator’s Breathing, MIL-PRF-27210
Liquid and Gas
Leak Detection Compound, Oxygen Systems MIL-PRF-25567
General Practices for MS33540

Safety Wiring and Cotter Pinning
Commercial Item Description Tape Antiseize, A-A-58092
Polytetrafluoroethylene
Code of Federal Regulations Hazardous Materials 49 CFR Parts 171 through 170
Regulations
Table 7003 / Assembly - Reference Documents
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TASK 35-31-55-400-802-A01
2. Pre-Assembly Information
A. (Refer to Table 7001) and (Refer to Table 7002) as required.
B. Unless noted otherwise, all preformed packings shall be lubricated with a thin film of
Fuel and Oxidizer Resistant Aircraft and Instrument Grease (Refer to Table 7002)
prior to installation.
C. Unless noted otherwise, all parts which require threading, twisting or turning operations
for assembly will be threaded, twisted or turned in a clockwise direction.
D. When indicated, apply Thread Sealing Tape (Refer to Table 7002) according to
Commercial Item Description Specification A-A-58092 (Refer to Table 7003).
E. When indicated, apply Lockwire (Refer to Table 7002) according to National Aeronautical
Standard MS33540 (Refer to Table 7003).
F. When indicated, apply Primer (Refer to Table 7002) and Adhesive (Refer to Table 7002)
in small amounts and wipe off excess with a clean cloth.
G. A “text arrow”, when used, shows the correct alignment of labels, decals and placards
put on the 807434, 9700, and 9800 Series PCA.
NOTE : Regulators with aluminum bodies ( (Refer to IPL FIG. 7), -55 thru -57) are
not repairable and have been superseded by regulators with brass bodies
(58, -59). If you have regulator assembly (-1, -1A, 2A) replace it with
regulator assembly (-2, -3).
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TASK 35-31-55-430-801-A01
3. Outlet Assemblies
A. Constant Flow (Metered) Type Outlet Assemblies

(Refer to SUBTASK 35-31-55-870-011-A01) to determine if a constant flow (metered)
outlet assembly is an “adjustable” or “precision” type.
After assembly, test all constant flow outlet assemblies (Refer to TASK
35-31-55-700-803-A01). Make sure that all constant flow assemblies pass all testing
requirements before use.
SUBTASK 35-31-55-440-001-A01
B. 5009-00, 5009 Series constant flow (metered) outlet assemblies
(1) 5009-00 “adjustable” type outlet assembly ( (Refer to IPL FIG. 1, IPL FIG. 1A, and
, IPL FIG. 1B, , 300; IPL FIG. 3), 1).
NOTE : The outlet assembly ( (Refer to IPL FIG. 3 , -1) is not procurable.
Replacement parts are not procurable for the outlet subassembly (6),
flow port (11), screen (4), filter (13), ring (12), gasket (14), glass
cord (5) or screw (3). If a replacement part is required, a complete
“precision” type outlet assembly must be ordered. Refer to Fig. 4) for
information on how to order a replacement “precision” outlet assembly.
(2) 5009 Series “precision” type outlet assemblies ( (Refer to IPL FIG. 1, IPL FIG. 1A,
and , IPL FIG. 1B, , 305; IPL FIG. 3), 1A thru 1K).
NOTE : The orifice ( (Refer to IPL FIG. 3 , 20), stud (7, 7A) and outlet
subassembly (6A) are not procurable. If a replacement part is
required, a complete outlet assembly must be ordered. Refer to Fig.
4) for information on how to order a replacement outlet assembly.
(a) Install the gasket ( (Refer to IPL FIG. 3), 14), valve (9) and spring (10) in
the receptacle (15).
(b) Apply a thin coat of the Aircraft and Instrument Grease (Refer to Table
7002) to the threads of the stud (7A)
(c) Install and tighten the receptacle (15) on the stud (7A). Install the dust
cover (2) on the receptacle.
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SUBTASK 35-31-55-440-002-A01
C. 5041-00, 5041 Series constant flow (metered) outlet assemblies
, IPL FIG. 1B, , 310; IPL FIG. 4), 1).
Replacement parts are not available for the coupling assembly (10),
screen (7, 9), glass cord (8), screw (6) and body (12). If a replacement
part is required, a complete “precision” type outlet assembly must
be ordered. Refer to Fig. 4) for information on how to order a
replacement “precision” outlet assembly.
and , IPL FIG. 1B, , 315; IPL FIG. 4), 1A thru 1K).
NOTE : The orifice ( (Refer to IPL FIG. 4 , 19), body (12A) and outlet
subassembly (10A) are not procurable. If a replacement part is
required, a complete outlet assembly must be ordered. Refer to Fig.
4) for information on how to order a replacement outlet assembly.
(a) Position the pins ( (Refer to IPL FIG. 4), 17) on the case (18) and hook the
springs (16) over the grooved end of the pins.
(b) Install the valve seat (15), valve (14) and spring (13) in the case (18).
(c) Apply a thin coat of the Aircraft and Instrument Grease (Refer to Table 7002)
to the threads of the body (12, 12A). Screw the case (18) onto the body (12,
12A) hand tight, then tighten one fourth to one third of a turn more.
(d) Thread the setscrew (11) into case (18). Hand tighten setscrew (11).
(e) If adjustment is required, loosen setscrew (11) and tighten or loosen case
(18) as required. After adjustment, torque setscrew (11) to 5-7 lbf-in.
(0.6-0.8 N.m).
(f) Install the washer (5) and cap (4) over the threads on the case (18).
(g) Assemble the nut (3) and cover assembly (2). Thread the nut (3) onto the
case (18).
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SUBTASK 35-31-55-440-003-A01
D. 5507-00, 5507 Series constant flow outlet assemblies
, IPL FIG. 1B, , 325; IPL FIG. 5), 1).
Replacement parts are not procurable for the outlet subassembly (5),
screen (4), glass cord (3), screw (2) and body (12). If a replacement
part is required, a complete “precision” type outlet assembly must
be ordered. Refer to Fig. 4) for information on how to order a
replacement “precision” outlet assembly.
and , IPL FIG. 1B, , 330; IPL FIG. 5), 1A thru 1G).
NOTE : The orifice ( (Refer to IPL FIG. 5 , 13) and body (12A) are not
procurable. If a replacement part is required, a complete outlet
assembly must be ordered. Do not reassemble the outlet assembly.
Refer to Fig. 4) for information on how to order a replacement outlet
assembly.
(a) Install the spring ( (Refer to IPL FIG. 5), 11, 11A), seat (10) or outlet poppet
(10A), washer (9) or outlet gasket (9A) and retaining washer (8) or outlet
washer (8A) in the body (12, 12A).
(b) Install lockwasher (7) or washer (7A) on the guide assembly (6) or threaded
adapter (6A).
(c) Screw the guide assembly (6) or threaded adapter (6A) into the body (12,
12A).
(d) Install the fillister head screw (6D) through the dust cover (6C) and torsion
spring (6B) into the body (12, 12A).
SUBTASK 35-31-55-440-004-A01
E. 5052-00 constant flow outlet assembly
NOTE : A replacement outlet assembly ( (Refer to IPL FIG. 6 , 1) or parts (2 thru 13)
are not procurable. If a complete assembly or a replacement part is required,
a “precision” type outlet assembly must be ordered. Refer to Fig. 4) for
information on how to order a replacement “precision” type outlet assembly.
(1) Assemble the coupling ( (Refer to IPL FIG. 6), 6) as follows unless noted
otherwise).
(a) Install the spring (9), retainer (12) into the body (13).
(b) Apply a thin coat of Aircraft and Instrument Grease (Refer to Table 7002)
to the valve seat gasket (11) and install the valve seat gasket on the valve
seat (10).
(c) Thread the valve seat (10) into the body (13) and tighten.
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(d) Apply a thin coat of Aircraft and Instrument Grease (Refer to Table 7002) to
the body gasket (8) and install the body gasket on the body (13).
(e) Thread the base (7) on the body (13) and tighten.
F. Full Flow (Non-metered) Type Outlet Assemblies

NOTE : After assembly, (Refer to TASK 35-31-55-700-803-A01) and test all full flow
outlet assemblies. Make sure that all full flow assemblies pass all testing
requirements before use.
SUBTASK 35-31-55-440-005-A01
(1) APN DPB153 outlet assembly
(a) A replacement outlet assembly or replacement parts are not procurable
for ( (Refer to IPL FIG. 1, IPL FIG. 1A, and , IPL FIG. 1B, , 350). Outlet
assembly (, IPL FIG. 1, , IPL FIG. 1A, and IPL FIG. 1B), 350) is replaced by
outlet assembly (355).
SUBTASK 35-31-55-440-006-A01
(2) APN 36728-01 outlet assembly
(a) Replacement parts are not procurable for this outlet assembly ( (Refer to
IPL FIG. 1, IPL FIG. 1A, and IPL FIG. 1B), 355). If replacement parts are
required, a complete outlet assembly must be ordered.
SUBTASK 35-31-55-440-007-A01
(3) APN 10008298 outlet assembly
(a) Replacement parts are not procurable for this outlet assembly ( (Refer to
IPL FIG. 1), 345). If replacement parts are required, a complete outlet
assembly must be ordered.
SUBTASK 35-31-55-440-008-A01
(4) APN 10003566 oxygen coupling
(a) A replacement oxygen coupling or replacement parts are not procurable.
The oxygen coupling ( (Refer to IPL FIG. 1 and , IPL FIG. 1B, , 335), is
replaced by outlet assembly (, IPL FIG. 1, and , IPL FIG. 1B, , 340; , IPL
FIG. 8, , 1). If a replacement oxygen coupling or replacement parts are
required, a complete outlet assembly (, IPL FIG. 1, and , IPL FIG. 1B, ,
340; IPL FIG. 8), 1) must be ordered.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-440-009-A01
(5) APN 802856-01 outlet assembly
(a) If removed during disassembly, install the warning label ( (Refer to IPL FIG.
8), 6) on the dust cover (5).
(b) Apply a thin coat of Aircraft and Instrument Grease (Refer to Table 7002) to
the quad ring (10), gasket (7A) and preformed packings (7, 12, 13).
(c) Install the preformed packing (12) on the disconnect body (11).
(d) Install the quad ring (10), preformed packing (13), disconnect poppet (9)
and poppet spring (8) in the disconnect body (11).
(e) Press the groove pins (4) into the disconnect fitting (3), if removed during
disassembly.
(f) Install the preformed packing (7) or gasket (7A) on the mating thread of the
disconnect fitting (3).
(g) Using the directions provided by the manufacturer, apply a thin coat of
Adhesive (Grade 222, (Refer to Table 7002)) on the first few exposed
threads at the end of the disconnect fitting (3). Thread the disconnect fitting
into the disconnect body (11). Tighten the disconnect fitting and wipe
excess Adhesive (if present) from the disconnect fitting and disconnect body.
(h) Install the dust cover retainer (2) on the disconnect fitting (3) and dust
cover (5). Twist and lock the dust cover (5) on the groove pins (4) of the
disconnect fitting (3).
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Page 7014
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-430-802-A01
4. Respirator Regulator
Unless noted otherwise, assembly procedures apply to both the demand ( (Refer to IPL FIG.
2), 1, 2) and demand/pressure-demand (2A, 3) type respirator regulators.
After assembly, perform the Respirator Regulator Tests (Refer to TASK 35-31-55-700-804-A01).
Make sure that the respirator regulator passes all the tests before use.
SUBTASK 35-31-55-440-014-A01
A. General Assembly
Assemble the following parts to the regulator case ( (Refer to IPL FIG. 2), 28, 28A).
(1) Attach the bracket ( (Refer to IPL FIG. 1B, 55) to the case (, IPL FIG. 2, , 28,
28A) with self-locking screws ( IPL FIG. 1B), 50). Tighten the self-locking screws.
(2) Apply Thread Sealing Tape to the mating threads of the connector assembly (10)
or tube connector (10A, 815).
(3) Install the screen ( (Refer to IPL FIG. 2, 27; , IPL FIG. 1B, , 850) in the case (,
IPL FIG. 2, , 28, 28A). Thread connector assembly (, IPL FIG. 1B, , 10) or tube
connector (10A, 815) into case ( IPL FIG. 2), 28, 28A) and tighten.
(4) Thread adapter (25, 26, 26A) into case (28, 28A). Tighten wrench tight.
SUBTASK 35-31-55-440-015-A01
B. Demand Valve Assembly
(1) Install valve seat gasket ( (Refer to IPL FIG. 2, 24, 24A; , IPL FIG. 1B, , 840) on
demand valve assembly (, IPL FIG. 2, , 20; IPL FIG. 1B), 830).
(2) Install and secure the demand valve assembly in the case ( (Refer to IPL FIG.
2, 28, 28A) with pan head screws (21, 21A), flat washers (, IPL FIG. 2, , 23,
23A; , IPL FIG. 1B, , 820) and lock washers ( IPL FIG. 2), 22, 22A). Tighten
the pan head screws.
SUBTASK 35-31-55-790-009-A01
C. Demand Valve Assembly Leak Test
(1) Use a high pressure connector having 0.125 - 27 ANPT threads and connect a
regulated source of clean, dry air to the inlet of case ( (Refer to IPL FIG. 2),
28, 28A).
(2) Apply 55 psig (0.38 MPa) pressure to the inlet of the case (28, 28A).
(3) Apply the Leak Detection Compound around the demand valve assembly ( (Refer
to IPL FIG. 2, 20; , IPL FIG. 1B, , 830), valve seat gasket (, IPL FIG. 2, , 24, 24A;
, IPL FIG. 1B, , 840), pan head screws (, IPL FIG. 2, 21, 21A), flat washers (,
IPL FIG. 2, , 23, 23A; , IPL FIG. 1B, , 820) and lock washers ( IPL FIG. 2), 22,
22A). There must be zero leakage. No bubbles in the Leak Detection Compound
is an indication of zero leakage.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(4) Reduce the inlet pressure to 0 psig (0 MPa). Discharge the remaining pressure
by pushing the demand valve assembly downward.
(5) Remove case (28, 28A) from the regulated air source. Remove the connector
from inlet of case.
(6) Dry all parts using clean, dry air.
(7) Remove the case (28, 28A) from the test setup.
SUBTASK 35-31-55-440-016-A01
D. Deflector (18)
CAUTION : A DEMAND VALVE ASSEMBLY HELD IN THE OPEN POSITION

BY CONTACT BETWEEN THE DEFLECTOR AND DEMAND VALVE
ASSEMBLY STEM MAY CAUSE THE RESPIRATOR REGULATOR
ASSEMBLY TO FAIL TO OPERATE PROPERLY.
(1) Carefully align the deflector ( (Refer to IPL FIG. 2, 18) over the demand valve
assembly (, IPL FIG. 2, , 20; , IPL FIG. 1B, , 830) and attach the deflector to the
case (, IPL FIG. 2, , 28, 28A) with pan head screws (, IPL FIG. 2, , 19, 19A; IPL
FIG. 1B), 835). Tighten the pan head screws.
(2) Make sure there is no contact between the deflector and the demand valve
assembly. Carefully bend the deflector if necessary.
SUBTASK 35-31-55-440-017-A01
E. Diaphragm Assembly
(1) Carefully install the diaphragm assembly ( (Refer to IPL FIG. 2, 16; , IPL FIG. 1B,
, 825) on the case ( IPL FIG. 2), 28, 28A) so that the diaphragm extends to the
lower edge of the grooved surface of the case. Make sure that the diaphragm is
seated evenly and not distorted (wrinkled).
NOTE : The diaphragm cord ( (Refer to IPL FIG. 2), 17) is not procurable.
The diaphragm cord (17) has been replaced by the diaphragm clamp
(17A). The diaphragm clamp must be used to secure the diaphragm to
the regulator case during assembly.
(2) Diaphragm clamp
(a) Put the wide edge of the beveled surface of the diaphragm clamp (17A)
toward the diaphragm assembly ( (Refer to IPL FIG. 2, 16; , IPL FIG. 1B,
, 825). Carefully push the diaphragm clamp ( IPL FIG. 2), 17A) over the
diaphragm assembly until the clamp is seated in the grooved area of the
case (28, 28A).
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-440-018-A01
F. Cover Assembly
NOTE : (Refer to Fig. 7001 , Fig. 7002, and Fig. 7003).
(1) Demand type cover assembly ( (Refer to IPL FIG. 2), 4)
(a) If necessary, put the respirator regulator S/N and DASH No. on the new
identification plate (8) with a metal stamp having 0.064 in. (1.63 mm) high
characters.
(b) Align and install the identification plates (8, 11) on the case cover (13) using
the rivets (10, 12).
(2) Demand/Pressure-Demand type cover assembly (5).
(a) If necessary, put the respirator regulator S/N and DASH No. on the new
identification plate (9) with a permanent black ink marker using 0.064 in.
(1.63 mm) high characters.
(b) Align and install the identification plate (15) on the case cover (14).
(c) Align and install the identification plate (9) on the case cover (14) using
the rivets (12).
(d) Position the case cover (14) so that the identification plate (9) is visible and
the “†”-shaped slot is facing up. Also, the 0.75 in. (1.9 cm) long raised lug
on the side of the case cover will be facing down.
(e) (Refer to Fig. 7002) to align and insert the “C”-shaped end of the slide
button (12D) through the lower slot (closest to the raised lug) of the case
cover (14). Align and insert the “T”-shaped end of the slide button through
the upper slot of the case cover.
(f) Hold the slide button (12D) in the case cover (14) and put the inside of the
case cover facing up. The raised lug will be facing down and both the slide
button and the identification plate (15) will be out of view.
(g) Carefully secure the slide button (12D) to the case cover (14) using the
spring (12C).
NOTE : Make sure the ends of the spring are secure and aligned under the
“C”-shaped and “T”- shaped ends of the slide button. Also, make sure
the long loop end of the spring faces away from the raised lug and
that the open side of the loop faces the center of the case cover.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
CAUTION : A PLATE W/ LEVER ASSEMBLY AND COMPRESSION SPRING

THAT ARE NOT PROPERLY POSITIONED MAY CAUSE THE
RESPIRATOR REGULATOR ASSEMBLY TO FAIL TO OPERATE
PROPERLY.
(h) (Refer to Fig. 7003 to locate and install the plate w/ lever assembly ( IPL
FIG. 2), 12B) in the “C”-shaped end of the slide button (12D). Also, the
end of the plate w/ lever assembly (12B) must be in the raised lug area of
the case cover (14).
WARNING : FAILURE TO WEAR GLOVES WHEN BENDING COMPRESSION

SPRING MAY RESULT IN INJURY TO THE HANDS.
(i) Measure and bend (if required) the compression spring (12A) until the length
is 3.25 ±0.06 in. (8.26 ±0.16 cm).
(j) Insert one end of the compression spring (12A) into the hole of the plate w/
lever assembly (12B). Insert the remaining end of the compression spring in
the lower (bottom) hole of the case cover (14).
(k) Hold finger pressure on the plate w/ lever assembly (12B) and push the
slide button (12D) between the demand and pressure-demand mode
settings. The slide button must operate freely. Put the slide button in the
demand mode position.
(l) Carefully locate and install the cover assembly (5) on the case (28, 28A).
Secure the cover assembly to the case using the pan head screws (7).
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Cover Assembly Identification Plate Placement

Figure 7001/GRAPHIC-35-31-55-991-100-A01
Slide Button and Spring Installation

Figure 7002/GRAPHIC-35-31-55-991-105-A01
Page 7019
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Plate w/ Lever Assembly and Compression Spring Installation

Figure 7003/GRAPHIC-35-31-55-991-110-A01
Page 7020
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-430-803-A01
5. Regulator Assembly
SUBTASK 35-31-55-440-019-A01
A. General Assembly
Install the following components in the regulator body ( (Refer to IPL FIG. 7), 58 thru 61).
(1) If necessary, transfer the regulator assembly PN, S/N and the Manufacture Date
from the original identification plate to a replacement identification plate (62, 63)
with a metal stamp having 0.064 in. (0.163 cm) characters. Install identification
plate on the body (58 thru 61) using drive screws (64).
(2) Install the spring (52), thrust pin guide (51), thrust pin (50) and seat (49) or seat
assembly (49A) in the body (55 thru 61).
(3) Carefully align the holder (48) over the thrust pin (50) and thread the holder into
the body (55 thru 61). Torque the holder to 50 lbf-in. (5.6 N.m).
CAUTION : THE DIAPHRAGM PLATE MUST BE INSTALLED WITH THE RAISED

CORNERS AWAY FROM THE DIAPHRAGM OR DAMAGE MAY
OCCUR TO THE DIAPHRAGM CAUSING THE REGULATOR TO
MALFUNCTION.
(4) Install the thrust plate (47), diaphragm ( (Refer to IPL FIG. 7, 46; , IPL FIG. 1, ,
IPL FIG. 1A, and , IPL FIG. 1B, , 755), diaphragm plate ( IPL FIG. 7), 44), slip ring
(45), adjusting spring (43) and spring guide (42, 42A) in the spring case (41, 41A).
(5) Put the body (55 thru 61) pointing up and carefully thread the spring case 41,
41A) onto the body (55 thru 61). Torque the case (41, 41A) to 175 - 225 lbf-in.
(19.8 - 25.4 N.m).
NOTE : Setscrew (40) must be used only with guide (42). Setscrew (40A)
must be used only with guide (42A).
(6) Thread the setscrew (40, 40A) into case (41, 41A) until it is even with the top
of case (41, 41A).
SUBTASK 35-31-55-440-020-A01
B. Safety Outlet Assembly
Assemble and install the safety outlet assembly in the body ( (Refer to IPL FIG. 7),
55 thru 61) as follows.
NOTE : Safety outlet replacement kit (26, ALT APN 26568-01) may be used as
a source of parts for, or to assemble a complete safety outlet assembly
(26). Kit contains items 28, 29, 32, 33, 34, Aircraft and Instrument
Grease, Lockwire, and assembly instruction sheet.
(1) Apply a thin layer of Aircraft and Instrument Grease (Refer to Table 7002) on the
gasket (32) and install the gasket in the safety plug (33).
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(2) Install the safety disc (29, 30) in the safety plug (33).
(3) Thread the safety cap (28) onto the safety plug (33). Torque the safety cap to 325
lbf-in. (36.7 N.m) when APN 7171-00 (29) safety disc is used. Torque the safety
cap to 350 lbf-in. (39.5 N.m) when APN 10003742 (30) safety disc is used.
(4) Lightly lubricate the safety plug washer ( (Refer to IPL FIG. 7, 34; , IPL FIG. 1, ,
IPL FIG. 1A, and , IPL FIG. 1B, , 770) with Molybdenum Disulfide (Refer to Table
7002) and install in the body ( IPL FIG. 7), 55 thru 61).
(5) Thread the safety outlet assembly (26, 27) into the body (55 thru 61). After the
safety outlet assembly (26, 27) is finger tight, rotate the safety outlet assembly
(26, 27) 45° ± 5°.
(6) Install Lockwire (Refer to Table 7002) between the safety cap (28) and the safety
plug (33).
SUBTASK 35-31-55-440-021-A01
C. Charging Valve Assembly
Install the charging valve assembly ( (Refer to IPL FIG. 7), 23) in the body (55 thru
61) as follows.
(1) Apply Thread Sealing Tape (Refer to Table 7002) to the charging valve (23) Install
the filter (23C) in the body (23A).
(2) Thread the charging valve into the body (55 thru 61).
(3) Torque charging valve to 175 - 225 lbf-in. (19.8 - 25.4 N.m).
SUBTASK 35-31-55-440-022-A01
D. On-Off Valve Kit
Assemble and install the on-off valve kit in the regulator assembly ( (Refer to IPL FIG.
7), 1 thru 5) as follows.
(1) Apply a thin layer of Aircraft and Instrument Grease (Refer to Table 7002) on the
valve stem assembly (15, 15A), preformed packings ( (Refer to IPL FIG. 7, 14,
14A, 18, 18A; , IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, , 775, 780) and
the threads of the valve head assembly (, IPL FIG. 7, , 17, 17A; , IPL FIG. 1, ,
IPL FIG. 1A, and IPL FIG. 1B), 800).
(2) Thread the head assembly ( (Refer to IPL FIG. 7, 17, 17A; , IPL FIG. 1, , IPL FIG.
1A, and , IPL FIG. 1B, 800) into the bushing ( IPL FIG. 7), 19).
(3) Install the PTFE seat ( (Refer to IPL FIG. 7, 16; , IPL FIG. 1, , IPL FIG. 1A, and ,
IPL FIG. 1B, , 760) on the valve stem assembly ( IPL FIG. 7), 15, 15A). Align the
stem assembly with the head assembly and install in the bushing (19).
(4) Install the preformed packing ( (Refer to IPL FIG. 7, 14, 14A; , IPL FIG. 1, , IPL
FIG. 1A, and , IPL FIG. 1B, , 775) on the packing nut ( IPL FIG. 7), 13).
Page 7022
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NOTE : Leave handle (8) unassembled until Valve Torque Test is performed
(Refer to SUBTASK 35-31-55-700-807-A01). Then go to Final
Assembly (Refer to SUBTASK 35-31-55-440-024-A01).
(5) Align the packing nut ( (Refer to IPL FIG. 7), 13) on the valve stem assembly (15,
15A) and thread the packing nut (13) into the bushing (19). Torque the packing
nut (13) to 140 - 160 lbf-in. (15.9 - 18.0 N.m).
(6) Install the filter ( (Refer to IPL FIG. 7, 20; , IPL FIG. 1, , IPL FIG. 1A, and , IPL
FIG. 1B, , 765) in the body ( IPL FIG. 7), 55 thru 61).
(7) Install the preformed packing ( (Refer to IPL FIG. 7, 18, 18A; , IPL FIG. 1, , IPL
FIG. 1A, and , IPL FIG. 1B, , 780) on the bushing ( IPL FIG. 7), 19).
(8) Thread the bushing (19) into the body (55 thru 61). Torque bushing to 175 -
200 lbf-in. (19.8 - 22.5 N.m).
(9) Put the On-Off Valve Kit (6, 6A) into the body (55 thru 61). Torque the On-Off
Valve Kit (6, 6A) to 200 lbf-in. (22.5 N.m).
(10) Install Lockwire (Refer to Table 7002) between packing nut (13) and body (55
thru 61) (Refer to Fig. 7004).
On-Off Valve Kit Installation

Figure 7004/GRAPHIC-35-31-55-991-115-A01
SUBTASK 35-31-55-440-023-A01
E. Gauge
Assemble and install the gauge as follows.
(1) If removed during disassembly, install the lens ( (Refer to IPL FIG. 9), 10, 10A),
bezel (5, 5A) and bezel w/ lens (15, 15A) on the gauge (1 thru 1E). If removed
during disassembly, install the bezel (7) on the gauge (1F).
(2) If removed during disassembly, install the relief label (25) and gasket (20) on
the gauge (1D, 1E).
(3) Perform the Gauge Accuracy Test (Refer to TASK 35-31-55-780-802-A01,) before
the gauge is installed on the regulator assembly. Make sure the gauge passes
the test before use.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(4) Apply Thread Sealing Tape (Refer to Table 7002) to the gauge ( (Refer to IPL
FIG. 7, 35, 36 36A; , IPL FIG. 9, , 1 thru 1F) and thread the gauge into the
body ( IPL FIG. 7), 55 thru 61). Align the gauge with a torque of 40 -150 lbf-in.
(4.5 - 16.9 N.m).
SUBTASK 35-31-55-700-807-A01
F. Testing
(1) Perform the Regulator Assembly Output Pressure Test (Refer to TASK
35-31-55-780-801-A01) described in the TESTING AND FAULT ISOLATION
section of this manual. Make sure the regulator assembly passes the test before
use.
(2) Perform the Valve Torque Test (Refer to TASK 35-31-55-700-805-A01) described
in the TESTING AND FAULT ISOLATION section of this manual. Make sure the
regulator assembly passes the test before use.
SUBTASK 35-31-55-440-024-A01
G. Final Assembly
Install the following components after performing the tests specified in Testing (Refer to
SUBTASK 35-31-55-700-807-A01).
Install the identification plate ( (Refer to IPL FIG. 7), 38; (Refer to IPL FIG. 1) (Refer to
IPL FIG. 1A) and (Refer to IPL FIG. 1B), 785) on the spring case. If the identification
plate ( (Refer to IPL FIG. 7), 38; (Refer to IPL FIG. 1) (Refer to IPL FIG. 1A) and
(Refer to IPL FIG. 1B), 785) is made from metal then attach it with the screws ( (Refer
to IPL FIG. 7), 39, 39A; (Refer to IPL FIG. 1) (Refer to IPL FIG. 1A) and (Refer to
IPL FIG. 1B), 805).
(1) (Refer to Fig. 7004 to align and install the flat washers ( IPL FIG. 7), 12), spring
washer (11) and handle (8) on the valve stem assembly (15, 15A). Secure the
handle on the stem assembly using self-locking hex nut (9C). Torque self-locking
hex nut (9C) to 20 - 25 lbf-in. (2.3 - 2.8 N.m). Do not exceed 25 lbf-in. (2.3 N.m)
or damage to the threads of the stem assembly or self-locking hex nut can occur.
NOTE : The nut ( (Refer to IPL FIG. 7), 9, 9A) and washer (10, 10A) are not
procurable. The self-locking hex nut (9C) replaces the nut (9, 9A,
9B) and washer (10, 10A). If you install the old flange hex nut (9B)
you must apply sealing compound grade 242 to the threads of the
flange hex nut (9B).
(2) Install the identification plate ( (Refer to IPL FIG. 7, 7; , IPL FIG. 1, , IPL FIG. 1A,
, IPL FIG. 1B, and , IPL FIG. 1C, , 790) on the handle ( IPL FIG. 7), 8).
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-420-801-A01
6. PCA Assembly
SUBTASK 35-31-55-420-001-A01
A. Regulator Assembly installed into steel cylinder
Install the regulator assembly in a steel cylinder ( (Refer to IPL FIG. 1), 500 thru 500C;
(Refer to IPL FIG. 1B), 500) as follows.
(1) Hold the cylinder ( (Refer to IPL FIG. 1, 500 thru 500C; IPL FIG. 1B), 500) in the
Pneumatic Bench Vise.
(2) Apply Thread Sealing Tape to the cylinder-mating threads on regulator assembly (
(Refer to IPL FIG. 7, 1 thru 3). Thread the regulator assembly into the steel
cylinder (, IPL FIG. 1, , 500 thru 500C; IPL FIG. 1B), 500) hand tight.
WARNING : AFTER THE CORRECT TORQUE HAS BEEN APPLIED, THE

REGULATOR BODY MUST HAVE A MINIMUM OF FOUR THREADS
ENGAGED WITH THE STEEL CYLINDER OR SERIOUS PERSONAL
INJURY OR DEATH MAY OCCUR WHEN THE PCA IS FILLED WITH
OXYGEN.
(3) Torque the regulator assembly ( (Refer to IPL FIG. 7, 1 thru 3) in the steel
cylinder (, IPL FIG. 1, , 500 thru 500C; IPL FIG. 1B), 500) to 480 - 840 lbf-in.
(54.2 - 94.9 N.m).
NOTE : The regulator body outlet port where the gauge ( (Refer to IPL FIG. 7
, 35) is installed must be aligned with the oxygen identification decal (,
IPL FIG. 1, and , IPL FIG. 1B, , 210, 215) on the cylinder (, IPL FIG.
1, , 500 thru 500C; IPL FIG. 1B), 500).
SUBTASK 35-31-55-440-099-A01
B. Regulator Assembly installed into composite cylinder
Install the regulator assembly in a composite cylinder ( (Refer to IPL FIG. 1A), 505;
(Refer to IPL FIG. 1C), 505) as follows.
(1) Apply a thin layer of Aircraft and Instrument Grease on the metal boss seal ( (Refer
to IPL FIG. 7), 54) or to the sealing surface of the preformed packing (54A) only.
(2) Install the metal boss seal (54) on the cylinder mating threads of the regulator
assembly (4, 5) with the sealing flange pointing away from the regulator.
(3) Install the preformed packing (54B) on the cylinder mating threads of the regulator
assembly (5A). Do not lubricate the threads of the regulator (5A).
Page 7025
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
CAUTION : FAILURE TO HOLD A COMPOSITE CYLINDER IN A PNEUMATIC

BENCH VISE MAY CAUSE DAMAGE TO THE FIBER OVER-WRAP
ON THE CYLINDER.
(4) Hold the cylinder ( (Refer to IPL FIG. 1A, 505; IPL FIG. 1C), 505) in the Pneumatic
Bench Vise.
(5) Thread the regulator assembly ( (Refer to IPL FIG. 7, 4, 5) into the composite
cylinder ( IPL FIG. 1A), 505) and torque to 540 - 660 lbf-in. (61.0 - 74.5 N.m).
(6) Thread the regulator assembly ( (Refer to IPL FIG. 7, 5A) into the composite
cylinder ( IPL FIG. 1C), 505) and torque to 600 - 840 lbf-in. (67.8 - 94.9 N.m).
, 36) is installed must be aligned with the oxygen identification decal (
IPL FIG. 1A), 210, 215) on the cylinder (505).
, 36A) is installed must be aligned with the identification label ( IPL
FIG. 1C), 220) on the cylinder (505).
SUBTASK 35-31-55-430-001-A01
C. Relief Valve Assembly
(1) Testing
(a) Perform the Relief Valve Assembly Test (Refer to TASK
35-31-55-700-802-A01) before the relief valve assembly is installed on the
regulator assembly. Make sure the relief valve assembly passes all the
tests before use.
(2) Apply Thread Sealing Tape on the relief valve assembly ( (Refer to IPL FIG. 7, 37)
and thread into the regulator assembly (, IPL FIG. 1, , 400 thru 410A; , IPL FIG.
1A, , 415, 420; , IPL FIG. 1B, , 400 thru 405A; , IPL FIG. 1C, , 415; IPL FIG. 7), 1
thru 5A). Torque the relief valve assembly to 75 - 100 lbf-in. (8.5 - 11.2 N.m).
SUBTASK 35-31-55-430-002-A01
D. Harness
(1) Install the upper end of the harness ( (Refer to IPL FIG. 1, IPL FIG. 1A, , IPL FIG.
1B, and , IPL FIG. 1C, , 100) or sling strap (, IPL FIG. 10, , 8) over the regulator
assembly (, IPL FIG. 1, , 400 thru 410A; , IPL FIG. 1A, , 415, 420; , IPL FIG. 1B, ,
400 thru 405A) and let it rest on the upper end (crown) of the cylinder (, IPL FIG.
1, , 500 thru 500C; , IPL FIG. 1A, , 505; , IPL FIG. 1B, , 500; IPL FIG. 1C), 505).
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SUBTASK 35-31-55-420-003-A01
E. Respirator Regulator Assembly
Install the respirator regulator as follows.
(1) Apply Thread Sealing Tape to the elbow assembly ( (Refer to IPL FIG. 1B), 15,
810).
(2) Thread the elbow assembly (15, 810) into the regulator assembly (400 thru 405).
Align and tighten the elbow assembly wrench tight.
(3) Install the clamp (60) through the bracket (55) onto the respirator regulator
assembly (-30, -35, 45).
(4) Install the clamp (-120) through the bracket (55) onto the respirator regulator
assembly (-40).
(5) Using the clamp (60, -120), loosely attach the respirator regulator assembly (30
thru 45) around the upper end of the cylinder (500).
(6) Remove the nut and ferrule (parts of the connector assembly or connector tube)
from the connector assembly (10) or connector tube (10A, 815) and install them
on the end of the elbow assembly (15, 810).
(7) Align the connector assembly (10) or connector tube (10A, 815) of the respirator
regulator assembly (30 thru 45) over the elbow assembly (15, 810). Push the
respirator regulator assembly onto the elbow assembly until the connector
assembly or connector tube is fully engaged. Thread the nut onto the connector
assembly (10) or connector tube (10A, 815) and tighten wrench tight.
(8) Tighten the clamp (60, 120) around the cylinder (500).
Page 7027
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-430-003-A01
F. Outlet Assemblies
Locate, install and mark the outlet assemblies as follows.
(1) Outlet assembly location and marking instructions.
The outlet assemblies used on 807434, 9700 Series and 9800 Series PCAs
are installed on the regulator assembly ( (Refer to IPL FIG. 1), 400 thru 410A;
(Refer to IPL FIG. 1A), 415, 420; (Refer to IPL FIG. 1B), 400 thru 405A; (Refer
to IPL FIG. 1C), 415; (Refer to IPL FIG. 7), 1 thru 5) in specific places and are
identified by special marks.
(Refer to Fig. 7005) and (Refer to Fig. 7006) for information about the location
and marks of outlet assemblies installed on the 807434, 9700 Series or 9800
Series PCAs. Also (Refer to Fig. 7007) for information about the location and
marking of outlet assemblies installed on 803668-01 PCA.
(a) Constant flow metered type outlet assemblies
1 On the 807434, 9700 Series PCA configured with more than one
constant flow (metered) type outlet assembly, the outlet assembly
with the highest flow rate is connected to the first regulator assembly
outlet port counterclockwise from the pressure gauge. On a 9800
Series PCA configured with more than one constant flow (metered)
type outlet assembly, the outlet assembly with the highest flow rate is
connected to the first regulator assembly outlet port counterclockwise
from the respirator regulator ( (Refer to IPL FIG. 1B), 30 thru 45).
2 When two constant flow (metered) outlets with different flow rates are
installed, there must be a mark on both outlets made with a rubber
stamp and Etching Ink. A “HI” mark, with Red Etching Ink, must be
put on the outlet assembly with the highest flow rate. A “LO” mark,
with Green Etching Ink, must be put on the outlet assembly with the
lowest flow rate.
3 All constant flow (metered) outlet assemblies must have the flow rate
and the altitude setting callout codes metal-stamped on the outside
of the outlet assembly. (Refer to Fig. 7) in the DESCRIPTION AND
OPERATION section if necessary.
(b) The full flow (non-metered) type outlet assembly ( (Refer to IPL FIG. 1, IPL
FIG. 1A, and , IPL FIG. 1B, , 335 thru 355 as applicable; , IPL FIG. 8,
, 1) is connected to the regulator assembly outlet port clockwise from the
on/off valve ( IPL FIG. 7), 6, 6A).
(2) Apply Thread Sealing Tape to the outlet assembly ( (Refer to IPL FIG. 1, IPL FIG.
1A, and , IPL FIG. 1B, , 300 thru 355 as applicable; , IPL FIG. 3, , 1 thru 1K; , IPL
FIG. 4, , 1 thru 1K; , IPL FIG. 5, , 1 thru 1G; , IPL FIG. 6, , 1; , IPL FIG. 7, , 70,
75; , IPL FIG. 8, , 1) or the plug (, IPL FIG. 1, , IPL FIG. 1A, and , IPL FIG. 1B, ,
360, 365) to be installed on the regulator assembly (, IPL FIG. 1, , 400 thru 410A;
, IPL FIG. 1A, , 415, 420; , IPL FIG. 1B, , 400 thru 405A; IPL FIG. 7), 1 thru 5).
Page 7028
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(3) Identify the correct location of each outlet assembly or plug on the regulator
assembly.
(4) Thread the outlet assembly or plug into the regulator assembly. Align the “HI” or
“LO” marks on the outlet assembly while torquing the outlet assembly or plug to
40 - 80 lbf-in. (4.5 - 9.0 N.m) - force. Make sure the “HI” or “LO” mark can be
seen from the top (regulator end) of the PCA.
(5) As needed, mark the constant flow (metered) outlet assembly ( (Refer to IPL FIG.
1, IPL FIG. 1A, and , IPL FIG. 1B, , 300 thru 330 as applicable; , IPL FIG. 3, , 1
thru 1K; , IPL FIG. 4, , 1 thru 1K; , IPL FIG. 5, , 1 thru 1G; , IPL FIG. 6, , 1; IPL
FIG. 7), 70, 75) with Etching Ink. Refer to step F.(1) if necessary.
(6) If removed during disassembly, apply outlet ID decals ( (Refer to IPL FIG. 10), 13,
14) on appropriate outlet assemblies used on 803668-01 PCA (1).
807434 and 9700 Series PCA Outlet Assembly Position and Markings
Figure 7005/GRAPHIC-35-31-55-991-120-A01
Page 7029
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
9800 Series PCA Outlet Assembly Position and Markings

Figure 7006/GRAPHIC-35-31-55-991-125-A01
9800 Series PCA Outlet Assembly Position and Markings

Figure 7007/GRAPHIC-35-31-55-991-130-A01
Page 7030
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
807434 and 9700 Series PCA Labeling

Figure 7008/GRAPHIC-35-31-55-991-135-A01
Page 7031
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
9800 Series PCA and 803668-01 PCA Labeling

Figure 7009/GRAPHIC-35-31-55-991-140-A01
SUBTASK 35-31-55-430-004-A01
G. ID decal
AVOX uses some non-procurable decals, identification plates and instruction plates in
the manufacture of the PCA. Replacement (procurable) decals, and plates noted in both
the IPL and this section may look different, however must contain the same information
as the non-procurable items.
All decals and plates requiring replacement have important information (i.e., part
number, serial number, dash number, date of manufacture, etc.) that must be put
on the replacement item before it is put on the cylinder ( (Refer to IPL FIG. 1), 500
thru 500C; (Refer to IPL FIG. 1A), 505; (Refer to IPL FIG. 1B), 500; (Refer to IPL
FIG. 1C), 505). A permanent ink marker pen may be used to mark information on the
replacement items with characters approximately the same height and spacing as those
contained on the original item.
NOTE : To find out if your AVOX product is FAA approved, refer to the
"AVOX Systems FAA approved parts list document No. 3900038" at
www.avoxsys.com or phone 1 716-683-5100.
FAA-PMA status information on the replacement item must be the same as that found
on the original item.
Locate, align and install decals, plates, placards, plates, and oxygen tag as follows (
(Refer to Fig. 7008) and (Refer to Fig. 7009)).
Page 7032
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(1) Apply the oxygen identification decal ( (Refer to IPL FIG. 1, IPL FIG. 1A, and , IPL
FIG. 1B, , 210, 215; , IPL FIG. 1C, , 215) on the cylinder (, IPL FIG. 1, , 500 thru
500C; , IPL FIG. 1A, , 505; , IPL FIG. 1B, , 500; IPL FIG. 1C), 505).
NOTE : A cylinder manufactured before 5/81 may have text painted on the
cylinder identical to that found on the oxygen identification decal.
Painted text, if present, will be placed on the cylinder the same as
the oxygen identification decal. Do not apply an oxygen identification
decal to a cylinder with painted text.
(2) Apply the operator instruction decal ( (Refer to IPL FIG. 1 and , IPL FIG. 1B, ,
200; , IPL FIG. 1, , IPL FIG. 1A, and IPL FIG. 1B), 205) as follows.
(a) Apply the instruction decal ( (Refer to IPL FIG. 1 and , IPL FIG. 1A, , 205)
to the 9700 Series PCA (, IPL FIG. 1, , 1 thru 2, 2C thru 2L; IPL FIG. 1A),
1 thru 1V).
(b) Apply the instruction decal ( (Refer to IPL FIG. 1B), 205) to the 9800 Series
PCA (1 thru 2F).
(3) Apply operating instruction placard ( (Refer to IPL FIG. 1), 235, 240) as follows.
(a) Apply operating instruction placard (235) on 9700-[ ]2[ ] Series PCA (2A).
(b) Apply operating instruction placard (240) on 9700-[ ]3[ ] Series (8J) PCA
(2B).
(4) Apply bottle inspection placard (230) on 9700 -[ ]2[ ] Series or 9700-[ ]3[ ] Series
PCA.
(5) Apply identification plate ( (Refer to IPL FIG. 1, IPL FIG. 1A, and IPL FIG. 1B),
220) as follows.
NOTE : Replacement identification plates used on 9700 Series or 9800 Series
PCA for aircraft applications other than those manufactured by The
Boeing Airplane Company in Seattle, Washington (Boeing) (i.e.,
aircraft models 707, 727, 737, 747, 757, 767 and 777) must be altered
by the user before being installed on the PCA.
(a) For identification plate ( (Refer to IPL FIG. 1), 225) on 9700 -AXX Series (1
thru 1D) or 9700 -DXX Series (2C, 2D) PCA do the following.
1 Refer to original identification plate and mark in or cross-out FAA-PMA
status information if applicable on replacement plate (225) before
proceeding to next step.
2 For Boeing aircraft applications, apply identification plate (225) on
PCA.
3 For non-Boeing aircraft applications, use permanent ink marker
to cross out the “Boeing PN 60B50087-XX” text on replacement
identification plate (225). Apply altered identification plate on PCA.
Page 7033
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(b) For identification plate (220) on 9700-CXX Series (1F thru 2B, 2K),
9700-FXX Series (2E thru 2J, 2L), 9700 -GXX Series ( (Refer to IPL FIG.
1A), -1 thru 1P, 1T thru 1V), or 9700 -HXX Series (-1Q thru 1S) PCA do
the following.
1 Refer to original identification plate. Cross-out FAA-PMA status
information if applicable on replacement plate ( (Refer to IPL FIG. 1),
220) before proceeding to next step.
PCA.
3 For non-Boeing aircraft applications, use permanent ink marker to
cross out the “Boeing PN 60B50087-XX” text on replacement plate
(220). Apply altered identification plate on PCA.
(c) For identification plate (220) on 9700 -B1X-BBF25A PCA (1E) used for NHA
803668-01 PCA ( (Refer to IPL FIG. 10), 1) do the following.
1 Refer to original identification plate. Mark-in or cross-out FAA-PMA
status information if applicable on replacement ( (Refer to IPL FIG. 1),
220) before proceeding to next step.
2 Use permanent ink marker and cross out the “Boeing PN
60B50087-XX” text on replacement identification plate (220). Also,
change “OXYGEN CAPACITY...” text from “11.00” cu ft to “7.15” cu ft.
Apply altered identification plate on PCA.
(d) For identification plate ( (Refer to IPL FIG. 1B), 220) on 9800 Series PCA
(1 thru 2F) do the following.
1 Refer to original identification plate. Mark-in or cross-out FAA-PMA
status information if applicable on replacement plate (220) before
proceeding to next step.
PCA.
3 For non-Boeing aircraft applications, use permanent ink marker
to cross out the “Boeing PN 60B50087-XX” text on replacement
identification plate (220). Apply altered identification plate on PCA.
(e) For identification plate ( (Refer to IPL FIG. 1C), 220) on 807434 Series PCA
(1): transfer AVOX PN, Customer PN, Mfg. Date, and Cu. Ft. information to
the replacement plate using a permanent ink marker and apply replacement
plate.
(6) Apply warning decal ( (Refer to IPL FIG. 1A), 245) on 9700 G2A and 9700 H2A
Series PCA (1 thru 1V).
(7) Apply warning decal ( (Refer to IPL FIG. 1C), 245) on 807434 Series PCA (1).
(8) Apply oxygen tag ( (Refer to IPL FIG. 10), 10) on 803668-01 PCA (1).
Page 7034
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-610-801-A01
7. PCA Charging Procedure
WARNING : 9700 SERIES, 9800 SERIES OR 803668-01 PCA EQUIPPED WITH A

DOT-3AA-1800 RATED STEEL CYLINDER WHICH DO NOT MEET ALL
REQUIREMENTS OF US DEPARTMENT OF TRANSPORTATION (DOT)
REGULATION 49 CFR 173.302A(B) MUST NOT BE PRESSURIZED IN
EXCESS OF THE MARKED ALLOWABLE SERVICE PRESSURE (1800
PSIG (12.41 MPA) OR THE CYLINDER DESIGN SPECIFICATIONS MAY BE
EXCEEDED ALLOWING A CYLINDER TO RUPTURE RESULTING IN FIRE,
EXPLOSION, SERIOUS PERSONAL INJURY OR DEATH.
9700 Series, 9800 Series and PN which meet all requirements of US DOT Regulation 49
CFR 173.302a(b) may be charged to a pressure 10 percent in excess of their marked service
pressure [(1800 psig (12.41 MPa) for US DOT-3AA-1800 steel cylinder at 70° F (21°C)].
Refer to chapter INSPECTION/CHECK for information on the hydrostatic testing period. If
the cylinder is not in compliance, it must be tested before refilling. A plus sign (+) following
the test date marking indicates that the cylinder is in compliance with US DOT Regulation
49 CFR 173.302a(b).
SUBTASK 35-31-55-610-001-A01
A. PCA Charging Setup
(1) Remove the filler cap ( (Refer to IPL FIG. 7), 21, 21A) from the charging valve (23).
(2) Attach the Refill Coupling (Refer to Table 7001) to the charging valve (23).
(3) Rotate knob (8) counterclockwise to fully open the on-off valve kit (6, 6A).
SUBTASK 35-31-55-610-002-A01
B. Charge the PCA
For correct charging procedure (Refer to Table 7003).
(a) CGA P-15 (Transfilling of Industrial and Medical Nonflammable Compressed
Gas Cylinders)
(b) SAE AIR1059 (Transfilling and Maintenance of Oxygen Cylinders)
(1) Refer to SAE AIR1059 or CGA P-15 for correct stabilized cylinder pressures at
ambient temperatures.
Page 7035
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-610-003-A01
C. Disconnect the PCA
WARNING : FAILURE TO FULLY DISCHARGE THE PCA CHARGING SETUP OF

OXYGEN BEFORE DISASSEMBLY OF ANY PART MAY RESULT IN
(1) Rotate handle ( (Refer to IPL FIG. 7), 8) clockwise to fully close on-off valve kit (6,
6A). Discharge all oxygen from the PCA charging setup.
(2) Remove the PCA from the PCA charging setup.
SUBTASK 35-31-55-700-899-A01
D. Testing
Perform the applicable PCA Final Test (Refer to TASK 35-31-55-700-806-A01). Make
sure PCA passes all tests before use.
Page 7036
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-400-803-A01
8. Final PCA Assembly
NOTE : The replacement PAX mask assembly ( (Refer to IPL FIG. 1), 150) may contain
either a cord & pin on the mask tubing or a loose-packed spring clip & tube which
must be removed and discarded. Carefully cut off the corner of the protective bag
containing the replacement (new) PAX mask assembly and remove either the
cord & pin from the mask tubing or the loose-packed spring clip & tube. Reseal
the protective bag with adhesive tape.
NOTE : The US FAA requires that at least one mask must be connected at all times to
each PCA that is onboard an aircraft for potential use (for operators covered
under 14 CFR Parts 25 and 121). Refer to chapter REWORK for detailed AVOX
recommendations for compliance.
SUBTASK 35-31-55-430-005-A01
A. P/N 801660-00 Harness Assembly
(Refer to Fig. 7010).
Install the harness ( (Refer to IPL FIG. 1), (Refer to IPL FIG. 1A), (Refer to IPL FIG. 1B)
and (Refer to IPL FIG. 1C), 100) as follows.
NOTE : The upper (loop) end of the harness was previously installed.
(1) Align the remaining end of the harness ( (Refer to IPL FIG. 1, , IPL FIG. 1A, ,
, IPL FIG. 1B, and , IPL FIG. 1C, , 100) on the lower end of the cylinder (, IPL
FIG. 1, , 500, 500B, thru 500C; , IPL FIG. 1A, , 505; , IPL FIG. 1B, , 500; IPL
FIG. 1C), 505).
(2) Align and install the clamp ( (Refer to IPL FIG. 1, , IPL FIG. 1A, , , IPL FIG. 1B,
and IPL FIG. 1C), 60) over the remaining end of harness. Depending on the
cylinder size, align and tighten the clamp on the cylinder approximately 2.5 in.
(6.4 cm) from the bottom end of cylinder.
Page 7037
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
PN 801660-00 Harness Configurations

Figure 7010/GRAPHIC-35-31-55-991-145-A01
SUBTASK 35-31-55-430-006-A01
B. P/N 801658-00 Harness Assembly
(Refer to Fig. 7011), (Refer to IPL FIG. 1) and (Refer to IPL FIG. 1B) unless noted
otherwise.
Install the harness assembly (105) as follows.
(1) Align and install the harness assembly (105) on the cylinder ( (Refer to IPL FIG.
1, 500B; IPL FIG. 1B), 500).
(2) Align and install the clamp (60) over the harness assembly (105). Depending on
the cylinder size, align and tighten the clamp on the cylinder approximately 2.5 in.
(6.4 cm) from the bottom end of cylinder.
(3) Align and install the clamp (120) over the harness assembly (105). Align and
tighten the clamp on the cylinder approximately 3.5 in. (8.9 cm) from the neck of
cylinder.
Page 7038
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
PN 801658 Harness Configuration

Figure 7011/GRAPHIC-35-31-55-991-150-A01
SUBTASK 35-31-55-430-007-A01
C. P/N 805118-01 Harness Assembly with Mask and Storage Bag
Install the harness assembly with mask and storage bag ( (Refer to IPL FIG. 1), 125)
as follows.
(1) Install the hook and loop fastener (145) through the mask storage bag assembly
(140).
(2) Align and install the fastener w/ the attached harness assembly with mask and
storage bag (125) on the PCA (2, 2A, 2B) approximately 9 in. (22.9 cm) from
the neck of the cylinder.
(3) Align and install the strap assembly (130) as follows.
(a) Align the strap assembly (130) on the cylinder (500B).
(b) Align and install the clamp (135) over the strap assembly (130). Align and
tighten the clamp on the cylinder approximately 3.5 in. (8.9 cm) from the
neck of cylinder.
(c) Align and install the clamp (60) over the remaining end of the strap assembly
(130). Depending on the cylinder size, align and tighten the clamp on the
cylinder approximately 2.5 in. (6.4 cm) from the bottom end of cylinder.
Page 7039
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(4) As necessary, repackage and install the passenger mask assembly (150) in the
mask storage bag assembly (140) as follows.
(a) Put the large diameter of the face piece down on a clean, flat, lint-free
surface and spread the reservoir bag out flat.
(b) Fold one third of the reservoir bag over the center of the bag parallel to
the tubing.
(c) Fold the other one third of the reservoir bag over the first folded side even
with the outer edge.
(d) Put the head strap into the face piece.
(e) Carefully put the folded reservoir bag into the face piece.
(f) Verify that the outlet assembly mating connector (155) is attached to the
tube.
(g) Coil the tube inside of the face piece in a clockwise direction.
(h) Put the PAX mask assembly in the protective plastic bag. Close and seal
the protective bag.
(i) Carefully put the sealed PAX mask assembly into the mask storage bag
assembly (140).
Page 7040
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
PN’s 805118-01, Mask Storage Bag and Harness Assembly

Figure 7012/GRAPHIC-35-31-55-991-155-A01
Page 7041
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-430-008-A01
D. P/N 803177-01 Harness Assembly with Mask and Storage Bag
(1) Install the sling strap ( (Refer to IPL FIG. 10), 8) as follows.
NOTE : The upper (loop) end of the sling strap (8) was previously installed.
(a) Align the remaining end of the sling strap (8) on the lower end of the cylinder
( (Refer to IPL FIG. 1), 500A).
(b) Align and install the clamp ( (Refer to IPL FIG. 10), 9) over the remaining end
of sling strap. Depending on the cylinder size, align and tighten the clamp on
the cylinder approximately 2.5 in. (6.4 cm) from the bottom end of cylinder.
(2) Install the harness assembly with mask and storage bag (3) as follows.
(a) Install the hook and loop fastener (5) through the mask storage bag
assembly (4).
(b) Align and install the hook and loop fastener w/ the attached harness
assembly with mask and storage bag (3) on the PCA (1) approximately 3.75
in. (9.53 cm) from the neck of the cylinder ( (Refer to IPL FIG. 1), 500A).
(3) As necessary, repackage and install the PAX mask assemblies ( (Refer to IPL
FIG. 10), 6, 6A) in the mask storage bag assembly (4) as follows.
NOTE : Replacement mask assembly, in stock will contain spring clip (PN
289-632) and spring clip tube (PN 289-640). Make sure you remove
and discard the spring clip and spring clip tube from the mask
assembly (6, 6A).
(a) Fold PAX Mask assembly No. 1 reservoir bag into thirds along the longer
axis.
(b) Fold the PAX Mask assembly reservoir bag in half also along the longer axis.
(c) Place the head strap into the face piece.
(d) Carefully place the folded reservoir bag into the face piece.
(e) Make sure that the plug-in connector (7) is attached to the tube.
(f) Coil the tube inside of the face piece in a clockwise direction.
(g) Repeat steps (a) thru (c) for PAX Mask assembly No. 2.
Page 7042
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(h) Place repackaged PAX Mask assembly No. 1 in face piece of PAX Mask
assembly No. 2.
(i) Carefully place folded reservoir bag (PAX Mask assembly No. 2) into face
piece of PAX Mask assembly No. 1.
(j) Make sure that the plug-in connector (7) is attached to the tube.
(k) Coil tube of PAX Mask assembly No. 2 around outside of PAX Mask
assemblies No. 1 and No. 2.
(l) Carefully put the packaged PAX mask assemblies into the mask storage
bag assembly (4).
Page 7043
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Mask Storage Bag Assembly Configuration

Figure 7013/GRAPHIC-35-31-55-991-160-A01
Page 7044
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-550-801-A01
9. Storage
Refer to chapter STORAGE.
Page 7045
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Page 7046
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-400-804-A01
10. Installation
Follow the applicable Aircraft Maintenance Manual for instructions on installing the PCA
onto an aircraft.
Page 7047
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Page 7048
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FITS AND CLEARANCES
TASK 35-31-55-992-801-A01
1. PORTABLE CYLINDER ASSEMBLY - FITS AND CLEARANCES
SUBTASK 35-31-55-992-001-A01
A. Table of Torque Values
(1) (Refer to Table 8001) for the torque values necessary to assemble the portable
oxygen cylinder assembly.
(2) Refer to the ILLUSTRATED PARTS LIST section of this manual for the item
numbers given in parentheses.
thru -500D.
TORQUE
IPL FIG. NO. AND ITEM NOMENCLATURE
lbf-in. N.m
1 - (300 - 355) Outlet Assembly 40 - 80 4.5 - 9.0
1A - (300 - 355)
1B - (300 - 355)
3 - (1 thru 1K)
4 - (1 thru 1K)
55 - (1 thru 1G)
6 - (1)
7 - (70, 75)
8 - (1)
1 - (360, 365) Plug 40 - 80 4.5 - 9.0
1A - (360, 365)
1B - (360, 365)
1 - (400 thru 410A) Regulator Assembly 480 - 840 54.2 - 94.9
1B - (400 thru 405A ) (0.500 - 14 ANPT
7 - (1 thru 3) Threads)
1A - (415, 420) Regulator Assembly 540 - 660 61.0 - 74.5
7 - (4, 5) (0.750 - 16UNF-2A
Threads)
1C - (415) Regulator Assembly 600 - 840 67.8 - 94.9
7 - (5A) (0.750 - 16UNF-2B
Threads)
4 - (11) Setscrew 5 - 7 0.6 - 0.8
7 - (9C) Flange Hex Nut 20 - 25 2.3 - 2.8
7 - (13) Packing Nut 140 - 160 15.9 - 18.0
7 - (19) Bushing 200 22.6
7 - (23) Charging Valve 175 - 225 19.8 - 25.4
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TORQUE
IPL FIG. NO. AND ITEM NOMENCLATURE
lbf-in. N.m
7 - (37) Relief Valve Assembly 75 - 100 8.5 - 11.2
7 - (48) Holder 50 5.6
7 - (28) Safety Cap Note 1 Note 1
7 - (35, 36) Gauge 40 -150 4.5 - 16.9
7 - (41, 41A) Case 175 - 225 19.8 - 25.4
NOTE: 1: Safety disc, APN 7171-00, is used in the safety outlet assembly (26, IPL Fig. 7).
Torque the safety cap to 325 lbf-in. (36.7 N.m) - force when safety disc APN 7171-00 (Item 29, IPL Fig. 7) is used.
Safety disc, APN 10003742, is used in the safety outlet assembly (27, IPL Fig. 7).
Torque the safety cap to 350 lbf-in. (39.5 N.m) - force when safety disc APN 10003742 (Item 30, IPL Fig. 7) is used.
Table 8001 / Torque Values
Page 8002
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES
TASK 35-31-55-940-801-A01
1. PORTABLE CYLINDER ASSEMBLY - SPECIAL TOOLS, FIXTURES, EQUIPMENT AND
CONSUMABLES
SUBTASK 35-31-55-940-001-A01
A. List of Special Tools, Fixtures and Equipment
(1) (Refer to Table 9001) for the specials tools, fixtures and equipment necessary to
do the maintenance of the portable cylinder assembly.
NOTE : Special tools, fixtures and equipment that you find to be equivalent
can be used as an alternative.
NAME RANGE ACCURACY SOURCE PAGE-

BLOCK
WHERE
USED
Mechanic standard NA NA Local supply 1001
tool kit 3001
6001
7001
11001
Pressure Gauge 0 - 100 psig (0 - 0.69 MPa) Minimum accuracy Ametek (US 1001
1404 Series 0 - 200 psig (0 - 1.38 MPa) ±0.25% full scale Gauge) 7001
0 - 2000 psig (0 - 13.8 MPa) Sellersville, PA 11001
18960-2625
USA (V61349)
Vent Valve NA NA Whitey Co. 1001
0.250 in. - 18 ANPT Highland
Threads Heights, OH
P4T Series 44134- 1533
B-4P4T4 USA (V12623)
Test Regulator 0 - 250 psig (0 - 1.72 MPa) NA Tescom Corp. 1001
44-1110 Series Outlet Pressure Elk River, MN 7001
44-1114 -24 0 - 2500 psig (0 - 17.2 MPa) 55330-2491
26-1600 Series Outlet Pressure USA (V5H64
26-1612-24 2)
Flowmeter 5.0 - 50 ccm Minimum accuracy Emerson 1001
1110 Series 13.6 - 136 ccm ±2% full scale Electric Co.
1110CC21ABGAA 0.62 - 6.20 lpm Brooks
1110CC11BBGAA 12.6 - 126 lpm Instruments
1110CC71DBGAA Division
1110CJ42CBGAA Hatfield, PA
19440-3052
USA (V91556)
Page 9001
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES

BLOCK
WHERE
USED
Mating Connector for: NA NA Avox Systems 1001
5009-00, 5009 Series (53655) 11001
Outlet Assy (5065-10)
5041-00, 5041
Series Outlet Assy
(29559-00)
5507-00, 5077
Series Outlet Assy
(14807-00)
5052-00 Outlet Assy
(5067-08)
10003566, 802856-01
Outlet Assy
(802857-01)
36728-01, DPB153
Outlet Assy
(36857-01)
(10007498)
Shut Off Valve (2 NA NA Whitey Co. 1001
required) Highland
1 Series Heights, OH
B-1VF4 44134-1533
USA (V12623)
Flow Control Valve NA NA Whitey Co. 1001
18 Series Highland
B-18RF8 Heights, OH
44134-1533
USA (V12623)
Needle Valve NA NA Whitey Co. 1001
1 Series Highland
B-1VF4 Heights, OH
44134-1533
USA (V12623)
Regulator Test Adapter NA NA Avox Systems 1001
0.500 - 14 ANPT x (53655)
0.250 - 18 ANPT
Threads
803213-S58-12
0.750 - 16UNF2A
x 0.250 - 18 ANPT
Threads
803213-S58-1
Page 9002
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES

BLOCK
WHERE
USED
Graduated Cylinder 5 NA NA Cole Parmer 1001
cc Capacity Instrument Co.
EW-34400-01 Vernon
Hills, NJ
60061-1844
USA (VKB50
0)
Low Pressure Vac to 2 psig (Vac to 14 KPa) Maximum inlet Fairchild 1001
Regulator (Vac to 55 in. WC) pressure is 250 psig Industrial
16 Series NOTE: REG requires both (1.72 MPa) Products Co.
16112J VAC and PRESS to operate. Winston-
Maximum inlet pressure is Salem, NC
250 psig (1,72 MPa) 27103-6708
USA (V07282)
Draft Gauge -5.0 to +5.0 in. WC (-12.7 to Minimum accuracy Dwyer 1001
2000 Series +12.7 cm WC) ±2% full scale Instruments
Magnehelic ®* Differential Pressure 0 to 15 Inc.
2310-A-321 in. WC (0 - 38 cm WC) Michigan
2015-A-321 City, IN
46360-0373
USA (V85274)
Respirator Regulator NA NA Avox Systems 1001
Mating Coupling (53655)
Threaded Type - For
assembly used on
9800-1 Series PCA
6210-00
AN Type Quick Disc -
For respirator regulator
assembly used on
9800-9 Series PCA
13822-00
Pneumatic Bench Vise NA NA Getz Fire 3001
Model BV-101-P Equipment Co. 7001
PN 58634 Peoria, IL
61602-1711
USA (V58013)
Protective Cap or Plug NA NA Local supply 4001
Inspection light NA NA Local supply 5001
6001
Magnifying glass NA NA Local supply 5001
Page 9003
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES

BLOCK
WHERE
USED
Spray Gun NA NA Binks 6001
Model 19 Manufacturing
Company
AMF Ohare,
IL 60666-2887
USA (V07334)
Cylinder Hanger NA NA Local supply 6001
(Steel Cylinders)
0.500 in. - 14 ANPT
Threads
Square Drive Plastic
Plug Fitting
Cross-Drilled for "S"
Hanger
Cylinder Hanger NA NA Local supply 6001
(Composite Cylinders)
0.750 - 16UNF-2A
Threads
Square Drive Plastic
Plug Fitting
Cross-Drilled for "S"
Hanger
Refill Coupling NA NA Avox Systems 7001
CGA 540 x 0.563 - (53655)
18UNF-2B Threads
5020-01
Leakage Tester NA NA Avox Systems 11001
5500-S58-6 (53655)
Test Plug NA NA Avox Systems 11001
5500-S58-7 (53655)
Cap NA NA Local supply 11001
* Magnehelic ® is a registered trademark of Dwyer Instruments Inc.
Table 9001 / Special Tools, Fixtures and Equipment
Page 9004
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SUBTASK 35-31-55-940-002-A01
B. List of Consumables
(1) (Refer to Table 9002) for the consumables necessary to do the maintenance of
the portable cylinder assembly.
NOTE : For oxygen lubricant, it is not permitted to use equivalent materials.
Other consumables that you find to be equivalent can be used as
an alternative.
(2) Also, Oxygen (MIL-PRF-27210, Type I or AS8010 Type I) is the Test Gas specified
in the TESTING AND FAULT ISOLATION section of this manual. Water pumped
Nitrogen (A-A-59503) or Air (equivalent in purity to MIL-PRF-27210, Type I) may
be substituted for Oxygen only when used as the Test Gas.
NAME PNR SUPPLIER’S CODE PAGE BLOCK WHERE

OR NAME AND USED
ADDRESS
Oxygen MIL-PRF-27210, Type 1 Local supply 1001
7001
Air BB-A-1034, Source 2, Local supply 1001
Grade A 7001
Nitrogen BB-N-411B, Type 1, Class Local supply 1001
1, Grade A 7001
Thread Sealing Tape PTFE Ribbon Tape Local supply 1001
0.250 in. (0.635 cm) wide CID A-A-58092, size 1 7001
Leak Detection MIL-PRF-25567, Type 1 Local supply 1001
Compound, Oxygen 7001
Systems
Non-ionic Detergent MIL-D-16791, Type I Local supply 4001
Sandpaper No specific Local supply 6001
320 Grit or Finer
Catalyst R6120 A.P. Nonweiler Co. 6001
Oshkosh, WI 54903-007
USA
Primer (2 part catalyzed 4285A093 A.P. Nonweiler Co. 6001
urethane) Light Gray (No. 36628 per Oshkosh, WI 54903-007
FED-STD-595) USA
Paint (2 part catalyzed 4285A073 A.P. Nonweiler Co. 6001
urethane): 4285K123 Oshkosh, WI 54903-007
Green (No. 24062 per USA
FED-STD-595)
Green (No. 14187per
FED-STD-595)
Paint, Green A2008-14090 Cardinal Industrial 6001
Lacquer Aerosol Spray Finishes
Can, 12 Oz. S. Elmonte, CA 91733
(No. 14090 Per USA
Fed-Std-595)
Page 9005
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
NAME PNR SUPPLIER’S CODE PAGE BLOCK WHERE

OR NAME AND USED
ADDRESS
Red and Green Etching PN S-1141 Marking Device 7001
Ink Manufacturing Co.
Philadelphia, PA
19133-2891
USA (V26040)
Lockwire MS20995C20 Local supply 7001
Primer No specific Loctite Corp. 7001
Grade T Rocky Hill, CT
06067-3582
USA (V05972)
Adhesive No specific Loctite Corp. 7001
Grade 222 Rocky Hill, CT
06067-3582
USA (V05972)
Sealing Compound No specific Loctite Corp. 7001
Grade 242 Rocky Hill, CT
06067-3582
USA (V05972)
Grease, Aircraft and MIL-PRF-27617, Type I Local supply 7001
Instrument, Fuel and
Oxidizer Resistant
Molybdenum Disulfide, AMS-M-7866 Local supply 7001
Technical, Lubrication
Grade
US DOT compliant 82009-22 Avox Systems (53655) 15001
reusable shipping box
Cylinder capacity 22 (cu.
ft.) and smaller
Polyethylene bag No specific Local supply 15001
Cardboard box No specific Local supply 15001
Cardboard or polystyrene No specific Local supply 15001
Adhesive tape No specific Local supply 15001
Desiccant No specific Local supply 15001
Transparent protection No specific Local supply 15001
support
Table 9002 / Consumables
Page 9006
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
SPECIAL PROCEDURES
TASK 35-31-55-610-802-A01
1. PORTABLE CYLINDER ASSEMBLY - SPECIAL PROCEDURES
A. General

EQUIPMENT. YOU CAN CAUSE A FIRE OR EXPLOSION.
CAUTION : IN ALL THE PROCEDURES, GASEOUS OXYGEN IS SPECIFIED AS

THE TEST GAS. GASEOUS NITROGEN (A-A-59503 TYPE 1, CLASS
1, GRADE A STANDARD) OR DRY AND OIL-FREE AIR (CRITERIA:
TOTAL HYDROCARBON: WEIGHT LESS THAN 6 PPM IN VOLUME
- SOLID PARTICLES: LESS THAN 10 MICROMETERS - WATER
CONTENT: LESS THAN 5 MG/M3 AT ATMOSPHERIC AMBIANCE
(EQUIVALENT DEW POINT: -63 °C (-81 °F) AT 760 MMHG)) CAN
REPLACE THE GASEOUS OXYGEN. THEN, YOU MUST DO A
CONVERSION OF THE RESULTS BEFORE YOU COMPARE THEM
WITH THE RESULTS SPECIFIED FOR THE GASEOUS OXYGEN. DO
NOT USE OIL-PUMPED GAS.

(a) This section contains information on special procedures used with for the
9700 Series and 9800 Series PCA.
Page 11001
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES

(a) (Refer to Table 11001) for the special tools, fixtures and equipment
necessary to do the maintenance of the components.
NAME QTY PNR SOURCE

Leakage Tester 1 5500-S58-6 Avox Systems (53655)
Test Plug 1 5500-S58-7 Avox Systems (53655)
Cap 1 No specific Local supply
Pressure Gauge 1 No specific Local supply
Range: 1 - 100 psi
Accuracy: ± 0.5 psi of full scale
Regulator Outlet Connector 1 DPB153¹, 10008298, Avox Systems (53655)
807434 or 9700 Series 36728-01, 5009 Series,
5041 Series, 5507 Series,
802856-01
Regulator Outlet Connector 1 DPB153¹, 36728-01, 5009 Avox Systems (53655)
9800 Series Series, 5041 Series, 5507
Series, 802856-01
NOTE : ¹ Intertechnique PN
Table 11001 / Special Tools, Fixtures and Equipment
SUBTASK 35-31-55-610-004-A01
C. Procedure for measuring residual pressure in oxygen cylinder and regulator assemblies
NOTE : (Incorporation of SIL-35-132)
It is important to know the pressure in oxygen cylinder and regulator assemblies when
no pressure is indicated on the installed pressure gauge. If the pressure is below
a certain level, the cylinder and regulator assembly can be shipped without use of
the special packaging required when fully charged. If the pressure in a cylinder and
regulator assembly is zero, then it must be assumed that the cylinder is contaminated
and requires internal cleaning.
Following is a procedure for measuring the pressure in an oxygen cylinder and regulator
assembly when the installed pressure gauge shows no pressure.
Page 11002
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES

SERVICE OR OVERHAUL PROCEDURES MAY CAUSE INJURY TO
THE EYES.
(1) Use eye protection at all times during all service or overhaul procedures.
WARNING : CONTAMINATION OF OXYGEN EQUIPMENT BY FAILING TO

HANDLE OXYGEN EQUIPMENT IN AN AREA CLEAN OF OIL,
GREASE, FLAMMABLE SOLVENTS, OR OTHER COMBUSTIBLE
MATERIALS INCLUDING DUST, LINT, AND FINE METAL PARTICLES;
CONTAMINATION FROM FAILING TO USE CLEAN HANDS, GLOVES,
TOOLS; OR CONTAMINATION BY ANY OTHER MEANS, WHEN
HANDLING OXYGEN EQUIPMENT, MAY RESULT IN FIRE OR
EXPLOSION THAT MAY CAUSE SERIOUS PERSONAL INJURY OR
DEATH.
(2) If oxygen equipment becomes contaminated with oil, grease, flammable solvents,
or other combustible materials, fire and explosion may occur. Also, many
substances and materials that do not normally burn in air, including dust, lint,
and fine metal particles can ignite in the presence of oxygen. Handle oxygen
equipment only in a clean area and with clean hands, gloves, tools, or other
means.
WARNING : DO NOT CONNECT THE LOW PRESSURE GAUGE TO ANY HIGH

PRESSURE PORT. IF THE LOW PRESSURE GAUGE IS CONNECTED
TO A HIGH PRESSURE PORT, IT CAN CAUSE DAMAGE TO THE
EQUIPMENT AND INJURY TO PERSONS.
(3) Do not connect the low pressure gauge to any high pressure port in the cylinder
and regulator assembly.
WARNING : DO NOT USE THIS PROCEDURE IF THE INSTALLED PRESSURE

GAUGE INDICATES A CYLINDER PRESSURE HIGHER THAN 100
PSIG OR PERSONS CAN BE INJURED AND EQUIPMENT CAN BE
DAMAGED.
(4) Do not do the following procedure if the installed pressure gauge indicates more
than 100 psig.
(5) Make sure the regulator is turned to “OFF”.
(6) Connect the pressure gauge to the low pressure outlet of the regulator using the
appropriate connector (Refer to Table 11001).
(7) Turn the regulator to “ON”.
Page 11003
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(8) Read the pressure from the gauge.

(9) Turn the regulator to “OFF”.
(10) Disconnect the pressure gauge from the regulator.
(11) If the pressure in step (8) exceeds 5 psi, the cylinder and regulator assembly
can be recharged.
SUBTASK 35-31-55-610-005-A01
D. Evacuation and Recharging Procedures for the 9700 and 9800 Series PCAs
NOTE : This information comes from SIL-35-149.
(1) Procedures
(a) Make sure the cylinder is clean, Refer to chapter CLEANING.
(b) If a 9800 Series PCA, unthread the nut on the connector ( (Refer to IPL
FIG. 1B), 10A) and remove the respirator regulator assembly (30, -35, -40,
-45) if necessary. Cover the end of the elbow (15) that is attached to the
regulator (400 thru 405A) with a cap capable of sealing against a vacuum
of 27 inches of mercury (91.5 kPa).
(c) Remove any low pressure PCA outlet ( (Refer to IPL FIG. 1A and IPL FIG.
1B))
(d) Thread the Leakage Tester (PN 5500-S58-6) into the empty port (wrench
tight).
(e) Attach the vacuum hose to the Leakage Tester (PN 5500-S58-6).
(f) Open the regulator On/Off Valve ( (Refer to IPL FIG. 7), 6, 6A).
NOTE : SAE AIR1059 recommends that after a cylinder has been cleaned and
the regulator replaced, the cylinder should be evacuated by drawing a
vacuum of 27 inches of mercury (91.5 kPa) for a period of 30 minutes
prior to refilling with oxygen.
(g) Turn on the vacuum source. Evacuate the cylinder to 27 inches Mercury
(91.5 kPa). (This step requires approximately one minute.)
(h) Close the regulator On/Off Valve (6, 6A). Turn off the vacuum source.
(i) Remove the Leakage Tester (PN 5500-S58-6) from the port.
(j) Thread the Test Plug (PN 5500-S58-7) into the same port.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(k) Remove the two setscrews (-39, 39A) holding ID plate (38) on the regulator
case (-41, 41A).
1 Remove the Cap (21A) from the Charging Valve (23).
2 Attach the refill coupling to the Charging Valve (23).
3 Fully open the On/Off Valve (6, 6A).
4 Charge the PCA, (Refer to TASK 35-31-55-610-801-A01,).
5 Close the On/Off Valve (6, 6A).
6 Remove the Test Plug (PN 5500-S58-7).
7 If a 9800 Series PCA, remove the cap used to seal the elbow ( (Refer
to IPL FIG. 1B), 15) against the vacuum in step (1)(b) above.
8 Complete the installation of the respirator regulator assembly (30, -35,
-40, -45), (Refer to SUBTASK 35-31-55-420-003-A01,).
(l) Remove the PCA from the Charging Setup.
(m) Re-install the ID plate ( (Refer to IPL FIG. 7), 38) on the regulator case (-41,
41A) using the two setscrews (-39, 39A).
(n) Re-install the low pressure outlet, (Refer to SUBTASK 35-31-55-430-003-
A01,).
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Page 11006
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
STORAGE
TASK 35-31-55-500-801-A01
1. PORTABLE CYLINDER ASSEMBLY - STORAGE
A. Job Set-Up Information
WARNING : STRICTLY OBEY THE PROCEDURES FOR THE STORAGE

AND TRANSPORT OF OXYGEN EQUIPMENT AS SPECIFIED IN
THE INTERNATIONAL AIR TRANSPORT ASSOCIATION (IATA)
SPECIFICATION UN1491:5.1. DO NOT USE OIL, GREASE OR OTHER
LUBRICANTS MADE FROM PETROL IN THE WORK AREA OF THIS
OXYGEN EQUIPMENT. THIS CAN CAUSE A DANGEROUS FIRE
HAZARD.
(1) This section contains information on storage (including transportation)

requirements for the 807434 Series, 9700 Series, and 9800 Series PCA.
(2) Consumables
(a) (Refer to Table 15001) for the consumables necessary to preserve, pack
and store the portable cylinder assembly.
an alternative.
NAME PNR SOURCE

US DOT compliant reusable 82009-22 Avox Systems (53655)
shipping box
Cylinder capacity 22 (cu. ft.) and
smaller
Polyethylene bag No specific Local supply
Cardboard box No specific Local supply
Cardboard or polystyrene No specific Local supply
Adhesive tape No specific Local supply
Desiccant No specific Local supply
Transparent protection support No specific Local supply
Table 15001 / Storage - Consumables
Page 15001
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES


Hazardous Materials Regulations 49 CFR Subchapter C, Parts 171 thru 180
Packaging of Airline Supplies ATA Specification No. 300
Table 15002 / Reference Documents
Page 15002
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-550-802-A01
2. Storage
A. General
(1) Ensure that the 807434, 9700, or 9800 Series PCA on/off valve (8, IPL Figure 7)
is in the “OFF” position before the PCA is transported or put in storage. Rotate
the handle (8, IPL Figure 7) fully clockwise to put the PCA in the “OFF” position.
(2) The PCA should always be transported or put in storage with a minimum positive
oxygen pressure to prevent contamination from entering. A PCA, even when
it contains a minimum amount of oxygen pressure, must still be stored and
transported under all applicable regulations. Refer to the CLEANING section in
this manual and clean the PCA if the cylinder becomes empty.
(3) Make sure all protective caps, plugs, and covers are tightly installed on the PCA.
(4) Put the PCA in a clean polyethylene bag and seal it for protection from dust
and dirt.
(5) Store the PCA in a cool area, away from sources of high heat and humidity.
Page 15003
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
TASK 35-31-55-500-802-A01
3. Transportation
SUBTASK 35-31-55-500-001-A01
A. Final Rule [(49 CFR 173.302a(f)(2)(i) and (ii))] (SIL-35-103)
The US Government has issued a Final Rule [(49 CFR 173.302a(f)(2)(i) and (ii))] on
the transportation of compressed oxygen cylinders by air. Part of this new rule sets
new requirements for pressure relief devices on compressed oxygen cylinders. This
provides information on AVOX Systems components that include compressed oxygen
cylinders which meet the new requirement.
Additional requirements and regulations (e.g., Transport Canada) for transport of oxygen
cylinders may apply in other countries.
The new rule does not apply to oxygen cylinders installed in and made part of an
aircraft. However, if any oxygen cylinder that is part of an aircraft is removed from the
aircraft, it must comply with the requirements of the new rule before it can be shipped
as freight or COMAT by air.
The new rule states in part that:
(1) Cylinders must be equipped with a pressure relief device in accordance with Sec.
173.301(f) and, beginning with the first requalification due after October 1, 2008:
(a) The rated burst pressure of a rupture disc for DOT 3AA cylinders must
be 100% of the cylinder minimum test pressure with a tolerance of -10 to
plus zero percent; and
(2) AVOX Systems PCAs
(a) This information applies to AVOX Systems PCAs that were manufactured at
any time by AVOX Systems or any of its predecessors.
(b) All AVOX System 807434/9700/9800 Series PCAs currently can be shipped
by air in accordance with the Hazardous Material and Transportation
regulations (49 CFR).
(c) The new rule on transporting oxygen cylinders requires that the pressure
relief devices of all cylinders transported as freight or COMAT by air meet
certain performance requirements. All AVOX Systems 807434 Series, 9700
Series, and 9800 Series PCAs listed in this manual include pressure relief
devices that meet the requirements of this new rule and can continue to be
transported as freight or COMAT by air in accordance with the Hazardous
Materials and Transportation regulations (49 CFR) after October 1, 2008
without further rework or adjustment.
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SUBTASK 35-31-55-510-001-A01
B. New US DOT HM224B Requirements
NOTE : (For air shipment of cylinder assemblies that contain compressed oxygen
into and within the US (Incorporating SIL-35-126))
(1) All cylinders charged with compressed oxygen gas greater than 29 psig at 68°
F (20° C) that are offered for air shipment within or into the US must comply
with US DOT HM224B packaging requirements. The ATA boxes that have been
used in recent years are no longer approved for transporting these cylinder
assemblies by air.
(2) Cylinders charged to less than 29 psig at 68° F (20° C) may be air shipped
without HM224B compliant packaging.
WARNING : THE PACKING FOR SHIPMENT AND OFFERING FOR SHIPMENT OF

ANY CHARGED COMPRESSED OXYGEN GAS CYLINDERS SHALL
BE DONE ONLY BY THOSE FACILITIES AUTHORIZED AND THOSE
PERSONNEL TRAINED TO HANDLE AND PACKAGE HAZARDOUS
MATERIAL. PERSONNEL ALSO NEED TO BE EXPERIENCED AND
KNOWLEDGEABLE IN HANDLING AVIATION OXYGEN EQUIPMENT.
FAILURE TO COMPLY MAY RESULT IN INJURY OR DEATH.
(3) Cylinders charged greater than 29 psig at 68° F (20° C) may be transported by:
(a) Surface transport by ship or truck in conventional packaging.
(b) Air transport in boxes compliant with HM224B in non-passenger aircraft
(Refer to Table 15001). The compliant boxes are marked with "DOT31FP."
(4) New US DOT HM224B Compliant Procedures
(a) Package securely in a box that is compliant with HM224B (Refer to Table
15001).
(b) This package may be offered for air shipment on any aircraft or surface
vehicle. (Air carriers may restrict the shipment of charged cylinders in
HM224B compliant boxes, e.g., they may limit the quantities carried.)
(c) HM224B compliant boxes are available for sale.
AVOX and Zodiac Services will provide the option to return any HM224B
boxes used for shipping of AVOX oxygen cylinder assemblies. The purchase
price of the box less a handling fee will be credited provided the box is
returned in good, usable condition.
The Return Material Authorization Number must be included on the Return
Material Authorization Form (Refer to Table 15003). The Return Material
Authorization Number must be provided by AVOX or Zodiac Services before
material is returned.
To get technical aid or to contact a Zodiac Services location, refer to
paragraph 1.I. in the INTRODUCTION section of this manual.
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(5) Shipment of cylinders charged to less than 29 psig at 68° F (20° C).
(a) Bleed the cylinder down to less than 25 psig at 68° F (20° C). Close the
cylinder valve.
(b) Affix the shipping tag (PN 10015660; see Figure 15001) securely to the
neck of the cylinder.
(c) Package in standard corrugated shipping boxes with appropriate dunnage to
protect and hold the cylinder assembly in place.
(d) Affix a label to the outside of the box that reads: "NON-HAZARDOUS.
LESS THAN 29 PSIG OXYGEN."
(e) Cylinders satisfying 3.C(5)(a) thru 3.C(5)(d) can be offered for shipment
to any destination by air or surface.
WARNING : CYLINDER ASSEMBLIES MUST BE FULLY CHARGED BEFORE

PLACING INTO SERVICE. FAILURE TO FULLY CHARGE A
CYLINDER BEFORE PLACING IN SERVICE MAY RESULT IN
INJURY OR DEATH.
(f) After arrival at destination

1 Charge the cylinder assembly to full operating pressure before placing
into service.
2 Remove the shipping tag PN 10015660 (Refer to Fig. 15001) from
the neck of the cylinder.
3 Verify that the cylinder is charged to full operating pressure.
4 Check the cylinder assembly for leaks.
5 Issue an EASA Form 1 or equivalent as required.
6 Add statement to block 13 on the EASA Form 1 or equivalent stating
that service was performed in accordance with the CMM.
7 Add in block 12 of the EASA Form 1 or equivalent “Inspected/Tested.”
8 Sign on the right side in block 20.
9 Install in aircraft or place in stores ready for service. OR
10 Re-package if unit is being forwarded (outside US only).
Page 15007
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Cylinder Shipping Tag PN 10015660

Figure 15001/GRAPHIC-35-31-55-991-235-A01
Page 15008
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(6) Return Material Authorization Number __________________________
Your Company Name:

Complete Shipping Address:
(Please do not use PO Boxes)
Country:
Telephone Number:
Fax Number:
E-mail Address:
US DOT HM224B Compliant Shipping Boxes
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
PN: S/N:
Table 15003 / Material Return Form
Page 15009
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Page 15010
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
REWORK
TASK 35-31-55-840-801-A01
1. New US FAA Rule (RIN 2120-AF77)
NOTE : At Least One Mask Must be Connected at all times to Each PCA Onboard an
Aircraft for Potential Use (SIL-35-51, SIL-35-54)
A. Summary
(1) The US FAA has issued a new rule (RIN 2120-AF77) covering operators under
14 CFR Parts 25 and 121. Under this new regulation, at least one mask must
be connected at all times to each Portable Cylinder Assembly (PCA) positioned
onboard an aircraft for potential use. The subject PCAs have a label with a
procedure for use.
The new regulation requires certain operators to pre-connect the mask to the PCA
placed onboard aircraft for potential use during flight. In those cases, because
the mask is connected to the PCA, the regulator should not be turned on until
the PCA is to be used. AVOX Systems is offering a free replacement Instruction
Label, which reflects this regulation, to those operators affected by this regulation.
One label is required for each PCA that the operator wants to change.
(2) In order to comply with this FAA Rule, existing PCAs with detached masks must
have those masks connected if the PCA is positioned for use onboard an aircraft
covered by this rule. It is recommended that PCAs used on aircraft covered
by this rule that were manufactured by AVOX Systems before June 1, 2006 be
labeled with the new procedure for use. The application of replacement labels is
voluntary, but recommended. The replacement Instruction Labels are available
free of charge from AVOX Systems.
B. Effectivity
(1) Aircraft
(a) This applies to all makes and models of aircraft that have any subject AVOX
Systems PCAs whether onboard or in spares storage for future use onboard
an aircraft. These PCAs may be installed in many different types of aircraft.
(2) Portable Cylinder Assemblies (PCAs)
(a) This applies to all PCAs listed in Table 16001 that were manufactured before
June 1, 2006. If your PCA has a yellow transparent label PN 10009071 or
PN 10009072, this applies. The new labels PN 10009071 03/06 and PN
10009072 03/06 are black print on silver. The text of the new label is shown
in Figure 16001.
Affected PCA 9700 Series 803668 Series 9800 Series

Instruction Label PN 10009072 03/06 10009072 03/06 10009071 03/06
Table 16001 / Affected PCAs and Replacement Instruction Label PNs
Page 16001
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(3) Materials
(a) One replacement Instruction Label PN 10009072 03/06 is required on
each subject 9700 Series PCA and 803668 Series PCA manufactured
before June 1, 2006 that the operator wants to replace the label on. One
replacement Instruction Label PN 10009071 03/06 is required on each
subject 9800 Series PCA manufactured before June 1, 2006 that the
operator wants to replace the label on. Replacement labels are available
free of charge from AVOX Systems.
(b) The use of a Mask Storage Bag may help protect your mask from physical
damage and contamination by dirt while the PCA is stowed with the mask
attached to it. If your PCA is not equipped with a mask Storage Bag, a Mask
Storage Bag Assembly (PN 801809-01) and a Velstrap* (PN 36879-01) for
attaching the mask storage bag to the PCA are available. (See Table 16002)
NOTE : The Velstrap* is suitable for attaching mask storage bags to
PCAs with cylinders as large as 22 ft³.
Replacement Instruction Labels PN 10009072 03/06 and PN 10009071 03/06

Figure 16001/GRAPHIC-35-31-55-991-021-A01
Page 16002
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Nomenclature Part Number Manufacturer

Instruction Label 10009072 03/06 Avox Systems (53655)
Instruction Label 10009072 03/06 Avox Systems (53655)
Mask Storage Bag 801809-01 Avox Systems (53655)
Velstrap* 36879-01 Avox Systems (53655)
NOTE: *Velstrap® is a registered trademark of Velcro Industries B.V.
Table 16002 / Material Information
C. Accomplishment
(1) Order enough replacement labels to re-label all the PCAs you want to re-label.
(2) For each PCA you want to re-label, remove the existing Instruction Label only if
loose or damaged, (Refer to Fig. 16002).
(3) Use soap and water to clean the existing label or the area on the cylinder from
where the Instruction Label was removed. Make sure the area is dry and free of
soap before the new label is affixed.
(4) Carefully affix a replacement Instruction Label (PN 10009071 03/06 or PN
10009072 03/06) shown in Figure 16001 in the area shown in Figure 16002 with
the text in the same orientation as the previous Instruction Label. If the existing
Instruction Label is clean and firmly adhered, the new label can be affixed over
it. Make sure that the Instruction label is tightly adhered to the cylinder by firmly
rubbing with your clean hand or a clean cloth.
(5) Replace the PCA with connected mask in your aircraft per the Aircraft
Maintenance Manual.
Page 16003
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Placement of Label on Cylinder

Figure 16002/GRAPHIC-35-31-55-991-240-A01
D. To Order Replacement Instruction Labels Free of Charge:
(1) To order replacement Instruction Labels free of charge, complete the Order Form
on the following page and email, fax or mail it to the contacts listed at the bottom
of the page.
E. To Buy a Mask Storage Bag or Velstrap®:
(1) To buy a Mask Storage Bag or Velstrap® contact one of the Zodiac Services
Distributors listed in Paragraph 1.I. in the INTRODUCTION section of this manual.
Page 16004
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
AVOX Systems PN 10009071 03/06 for 9800 Series PCA

AVOX Systems PN 10009072 03/06 for 9700 Series or 803668 Series PCA
Your Company Name:
Complete Shipping Address:
(No P.O. Boxes please)
Country:
Telephone Number:
Fax Number:
E-mail Address:
Aircraft Type(s) PCAs used on:
Complete PCA Part Number(s):
AVOX Label Part Number Quantity of Labels Requested
PN 10009071 03/06 _____________________
PN 10009072 03/06 _____________________
E-mail the completed form to AVOX Systems at CustomerService.Avox@zodiacaerospace.com
Table 16003 / LABEL ORDER FORM
Page 16005
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Page 16006
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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
ILLUSTRATED PARTS LIST
IPL 10001 Page 1

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IPL 10001 Page 2

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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
INTRODUCTION TO THE ILLUSTRATED PARTS LIST
TASK 35-31-55-990-850-A01
1. Introduction
A. General
(1) The purpose of this IPL is the identification of equipment assemblies,
sub-assemblies, and parts.
(2) It is set up in conformance with the rules set forth in ATA 2200, revision 2000-1.
(3) From time to time, the illustrated nomenclature is revised so as to incorporate
recent additions, cancellations and modifications in equipment. Revisions are
indicated by an "R" on the right of each revised line, and apply solely to the
date of revision.
B. Use of the IPL

(1) Publication format
(a) The IPL is arranged in the following order:
– Introduction, including the Vendor Code Index (VCI)
– Equipment Designator Index (EDI)
– Numerical Index (NI)
– Detailed Parts List (DPL).
(b) Equipment designator index
This index contains the relevant reference and diagrams for each circuit
symbol, as well as the corresponding marker.
The equipment designator index is alphanumerical, and is arranged in the
following order:
– Dash
– Letters from A through Z
– Numerals from 0 through 9.
(c) Numerical index
This index contains all Part Numbers (PN) ever included in the Detailed
Parts. The part number is followed by the applicable figure and item number
/ variant references.
The numerical index is alphanumerical, and is arranged in the following
order:
– Dash
– Letters from A through Z
– Numerals from 0 through 9.
INTRO 10001 Page 1

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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(d) Vendor Code index

The vendor code index is alphanumerically arranged according to the
manufacturer's code. This list includes the names and addresses of all
manufacturers cited in the detailed nomenclature.
(2) Identification of a component part
There are several different ways to identify a component part.
(a) To find a part with a known Part Number (PN)
1 Refer to the Numerical Index and find the PN.
2 The numerical index contains the following information about the
reference:
– The reference of the part specific to the airline (column left blank)
– The illustrated catalog sequence number (CSN). Application:
2-150A (2 = Figure number, 150A = sequence number)
– The quantity per CSN.
3 Refer to the figure in the parts list.
4 Find the item number on the illustration.
(b) To find a PN with a known Equipment Designator Index.
This index specifies the item reference and the CSN relevant to a given
symbol.
1 A circuit symbol is made up of:
– 1 or 2 letters specifying the nature of the component part (letter
symbol)
– 1 or 2 numerals stating the order code of the component part
in the relevant sub-assembly
– Or possibly with a position suffix, containing 2 or 4 numerals,
and defining the sub-assembly in which the component part is
mounted. This suffix is chosen at random.
Application: R10 - 6
R = Letter Symbol
10 = Order No
6 = Position suffix.
2 List of position suffixes versus the sub-assembly designation.
FIGURE DESIGNATION SUFFIX

1 Refuel panel multi tank indicator (MTI), assembly 10
2 Circuit card display 20
3 Circuit card assembly, CPU 32
INTRO 10001 Page 2

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3 List of sub-assemblies versus the position suffix number.
SUFFIX DESIGNATION FIGURE

10 Refuel panel multi tank indicator (MTI), assembly 1
20 Circuit card display 2
30 Circuit card assembly, CPU 3
(c) To find a PN through the illustrated nomenclature:

1 Find the illustration that shows the breakdown of the assembly.
2 Find the part and make a note of the item number.
3 Look in the parts list related to the illustration for the item number.
This will also gives you the QTY (quantity) and the description.
C. Use of the Detailed Parts List

(1) The detailed parts list includes the nomenclature and illustrations of the unit
components.
– 1st column : Figure and Item/Item variant number
– 2nd column : Part Number
– 3rd column : Airline Part Number
– 4th column : Nomenclature
– 5th column : Usage Code
– 6th column : Units per Assembly.
(2) Figure and Item Numbers
(a) An item number is given to each part-numbered assembly, sub-assembly or
item in the parts list.
(b) The figure number, which includes the items in the list, is given on the first
line at the top of each page.
(c) The highest assemblies for each figure shall be listed first. If there is more
than one part number for an assembly, use alpha variant item numbers
e.g. 1A, 1B, 10A, 10B etc. In the usage code column of the assembly
parts, the letters are used to link parts to the correct assembly. Use alpha
variant item numbers for:
– Parts introduced by modification, product improvement, change of
material etc
– Similar parts with different usage code
– Optional parts, unless an alpha variant is listed for another reason. In
this case, optional part numbers must be given in the Nomenclature
column.
(d) Assemblies, sub-assemblies and parts in the list which are not illustrated
are identified with a dash (-) before the item number.
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(3) Manufacturer's Part Number

(a) A manufacturer's part number is given to each assembly, sub-assembly
and detail parts (illustrated or not).
(4) Nomenclature
(a) Use the indenture system of a number in the indent column next to the
Nomenclature column to show how parts and assemblies relate to Next
Higher Assemblies (NHA), as follows:
1 2 3 4 5 6 7
Assembly
. Detail parts of assembly
. Subassembly
Attaching parts and/or storage parts for sub-assembly
* * *
. . Detail parts for sub-assembly
Sub-subassembly
Attaching parts and/or storage parts for sub-subassembly
* * *
. . . Detail parts for sub-subassembly
etc...
(b) A vendor code is given for all items or articles not made by the prime
manufacturer of the assembly.
(c) This vendor code or the abbreviation "NP" (Non Procurable) is written at the
far right-hand side in the first line of the nomenclature.
(5) Effectivity Code
(a) In a figure, the part number identified by an effectivity code shows that the
coded part must be used with other parts identified with the same alpha
designation. Also, coded parts can be used with all other non-coded parts
(no alpha designation).
(b) The effectivity code must begin with A and continue with B, C, ... Z. If
required, the succession will follow BA, CA, DA ... ZA, CB, DB, EB, ... DC,
EC, FC, etc. The succession will always begin with the subsequent alpha
set which follows the last set by one alpha.
(6) Units Per Assembly
(a) The units per assembly column shows the number of necessary units for the
subsequent higher assembly. In some cases, the letters "RF" (Reference)
or "AR" (As Required) replace this information.
INTRO 10001 Page 4

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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(7) Abbreviations
– AR = As required
– DET = Detail
– LH and RH = Left and right
– NHA = Next higher assembly
– NP = Non procurable
– OLD PN = Old part number
– ORDER OVERLGTH MPN = Actual part number is more than 15 characters
– OVERSIZE = Oversize repair parts
– R = Modified
– RF = For reference
– SEL FROM = Select from parts
– POST SB = Post Service Bulletin
– POST SL = Post Service Letter
– REPLD = Replaced By (refer to Interchangeability)
– REPLS = Replaces (refer to Interchangeability)
– SUPSD BY = Superseded by
– SUPSDS = Supersedes
– UNDERSIZE = Undersize repair parts.
(a) Interchangeability
1 PNR replaced by : 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).
2 PNR replaces : 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).
3 PNR superseded by : 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).
4 PNR supersedes: The part supersedes and is one-way
interchangeable with the item number shown (new part number is
acceptable replacement for old or new part number).
INTRO 10001 Page 5

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803668-01, 807434-01, 9700 SERIES, 9800 SERIES
(b) The following letters are used in the standard index :
T tera = 10exp(12)
G giga = 10exp(9)
M mega = 10exp(6)
K kilo = 10exp(3)
U one = 1
MY milli = 10exp(-3)
MU micro = 10exp(-6)
N nano = 10exp(-9)
P pico = 10exp(-12)
(c) The following letters are used in the standard index to indicate tolerances
on electronic components.
B 0.1%
C 0.25%
D 0.50%
F 1%
G 2%
J 5%
K 10%
(8) Updating
(a) When an item is revised, added or deleted, a vertical line is added in the left
margin (the page date of issue changes).
INTRO 10001 Page 6

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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
VENDOR'S CODE INDEX
VENDOR CODE NAME ADDRESS

VF53418 EROS EQUIPEMENTS RESPIRATOIRES A OXYGENE DE SECOURS
GIE 61 R Pierre Curie Plaisir FRANCE78371
V21343 Owens-Corning Fiberglass Corp. Huntingdon, PA 16652-0382 USA
V49315 Puritan Bennett Corp. Shawnee Mission, KS 66225 USA
V53655 AVOX Systems Lancaster, NY 14086-9502 USA
V80205 National Aeronautical Standards (NAS) Aerospace Industries Association
of America Washington, DC 20005 USA
V880445 Aeronautical Standards (AN) Department of Army and Navy USA
V95138 Perfecting Corp. Charlotte, NC 28206 USA
V96906 Military Standards (MS) USA
VCI 10001 Page 1

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VCI 10001 Page 2

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
ALPHA NUMERICAL INDEX
FIGURE ITEM TOTAL

PART NUMBER AIRLINE PART NUMBER
NUMBER NUMBER REQUIRED
10001296 1B 55 1
10001493 3 11 1
10001494 3 7 1
10002408 7 63 1
10002538 1 220 1
10002539 1B 220 1
10002542 1 - 200 1
10002543 1B - 200 1
10002684 7 - 23C 1
10003202 1 - 225 1
10003209 7 - 56 1
10003305 7 - 53A 1
10003319 7 - 57 1
10003566 1 335 1
1B 335 1
10003742 7 30 1
10005614 8 3 1
10005615 8 11 1
10005616 8 9 1
10005617 8 5 1
10005927 1 - 210 1
1A - 210 1
1B - 210 1
10006001 7 - 31 1
10006442 1A - 245 1
10007468 2 15 1
10007721 10 - 11 1
10007729 10 10 1
10007738 10 13 2
10007739 10 14 1
10007887 7 15A 1
10008298 1 345 2
345A 1
10008459 1C 245 1
10008594 5 110 1
11A 1
10008595 5 50 1
6C 1
10008596 5 40 1
6B 1
10008601 5 80 1
8A 1
10008602 5 90 1
9A 1
10008603 5 100 1
10A 1
10008644 8 2 1
NI/ALPHA 10001 Page 1

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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

10008660 5 60 1
6D 1
10008774 5 70 1
7A 1
10008915 3 7A 1
10008934 4 12A 1
80 1
10008947 5 120 1
12A 1
10008980 1A 220 1
10009071 1B 205 1
10009072 1 205 1
1A 205 1
10009255 1 215 1
1A 215 1
1B 215 1
1C 215 1
10009328 8 7A 1
10009359 2 17A 1
10010747 1 - 235 1
10010748 1 - 230 1
10010859 1 - 240 1
10012606 1C 220 1
10013868 7 - 54A 1
10015704 1 - 770A 1
1A - 770A 1
1B - 770A 1
7 34A 1
13160-00 1 120 1
135 1
60 1
10 9 1
1A 60 1
1B - 120 1
- 75 1
60 2
1C 60 1
13164-00 2 - 26C 1
13362-00 1B - 840 1
2 24A 1
13374-00 1B - 825 1
2 16 1
13753-00 9 10 1
14807-00 1 155 1
18037-01 7 - 18 1
210331 5 - 6 1
21217-11 9 5A 1

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

21217-12 9 10A 1
21217-13 9 20 1
21217-14 9 25 1
21507-06 1A - 510 1
505 1
22427-01 1 - 790 1
1A - 790 1
1B - 790 1
7 7 1
22445-01 7 11 1
23274-05 7 8 1
23393-01 7 19 1
23394-01 7 13 1
24823-00 3 9 1
24825-00 3 15 1
26565-00 7 28 1
26567-00 7 33 1
2661-03 7 35 1
9 1 RF
1A RF
1B RF
1C RF
1D RF
2661-04 7 - 36 1
9 1E RF
27170-01 7 - 58 1
27170-02 7 - 59 1
27170-05 7 - 60 1
27170-06 7 - 61 1
27511-01 8 6 1
2800C10A 8 13 1
2800C14A 8 12 1
28021-00 1B - 750 1
28022-00 1 - 750 1
10 - 50 1
1A - 750 1
289-601-211 10 6A 2
289-601-211-2 10 - 6 2
289-601-214 1 150 1
289-601-434 1 - 150A 1
29550-00 4 12 1
29551-00 4 13 1
90 1
29552-00 4 100 1
14 1
29553-01 4 110 1
15 1

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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

29554-00 4 140 1
18 1
29555-00 4 120 2
16 2
29556-00 4 130 2
17 2
29557-00 4 3 1
40 1
29558-01 4 2 1
30 1
29567-00 4 11 1
70 1
32008-02 1 - 810 1
33321-213 1B - 860 2
33529-009 1B - 815 1
10A 1
36588-04 8 8 1
36636-01 8 10 1
36728-01 1 355 1
355A 2
355B 3
1A 355 1
1B 355 1
36862-02 8 - 7 1
36874-01 8 4 2
36879-01 1 145 1
10 - 5 1
37008-01 7 - 40 1
37008-02 1 - 810A 1
1A - 810 1
1B - 855 1
7 40A 1
5002-00 7 51 1
5003-00 7 43 1
5005-01 7 - 41 1
5005-03 7 41A 1
5009-00 1 300 1
1A 300 1
1B 300 1
3 - 1 RF
5009-01 3 - 6 1
5009-2-10 1A 305 1
3 - 1A RF
5009-2-20 1 305 1
1A 305A 1
3 - 1B RF
5009-2-23 1 305A 1

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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

305B 2
1A 305B 1
1B 305 1
3 - 1C RF
5009-2-25 1 305C 2
305D 1
1A 305F 1
3 - 1D RF
5009-3-20 1B 305A 1
3 - 1E RF
5009-3-23 1B 305B 1
3 - 1F RF
5009-4-10 1A 305C 1
3 - 1G RF
5009-4-20 1 305E 1
1A 305D 1
1B 305C 1
3 - 1H RF
5009-4-23 1 305F 1
305H 2
1A 305E 1
1B 305D 1
3 - 1J RF
5009-4-25 1 305G 1
1A 305G 1
3 - 1K RF
5013-00 3 4 1
6 4 2
5013-01 4 7 1
9 AR
5 4 2
5014-00 3 3 1
6 2 1
5014-01 4 6 1
5 2 1
5016-00 7 - 21 1
5018-00 7 - 53 1
5023-00 7 - 22 1
5027-00 7 52 1
5028-00 7 50 1
5029-00 7 - 49 1
5030-01 7 48 1
5031-00 7 47 1
5032-01 1 - 755 1
1A - 755 1
1B - 755 1
7 46 1

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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

5033-00 7 - 45 3
45B 1
5033-02 7 45A 1
5034-00 7 44 1
5041-00 1 310 1
1A 310 1
1B 310 1
4 - 1 1
5041-01 4 - 10 1
5041-2-10 1A 315 1
4 - 1A RF
5041-2-20 1 315 1
315A 2
1A 315A 1
1B 315 1
4 - 1B RF
5041-2-23 1 315B 1
1A 315B 1
4 - 1C RF
5041-3-20 1B 315A 1
4 - 1D RF
5041-3-23 1B 315B 1
4 - 1E RF
5041-4-10 1A 315C 1
4 - 1F RF
5041-4-20 1 315C 1
1A 315D 1
1B 315C 1
4 - 1G RF
5041-4-23 1 315D 1
1A 315E 1
1B 315D 1
4 - 1H RF
5041-4-25 1A 315F 2
315G 1
4 - 1J RF
5041-5-15 4 - 1K RF
7 70 1
75 1
5042-01 4 4 1
50 1
5042-02 4 5 1
60 1
5043-14 7 37 1
37A 1
5052-00 1 320 2
320A 1

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

1B 320 1
320A 1
6 - 1 RF
5052-02 6 - 6 1
5053-07 7 - 55 1
5056-00 1 - 785 1
1A - 785 1
1B - 785 1
7 38 1
5057-14 7 - 62 1
5058-00 6 5 1
5065-02 3 12 1
5065-03 3 14 1
5065-04 3 13 1
5065-06 3 10 1
5065-08 3 8 1
5065-10 10 - 7 2
5067-01 6 7 1
5067-02 6 8 1
5067-03 6 13 1
5067-04 6 9 1
5067-05 6 12 1
5067-06 6 11 1
5067-07 6 10 1
50775SERIES 3 20 1
4 - 19 1
5 13 1
5092-00 7 - 23A 1
5093-01 7 23 1
520058 5 - 10 1
5507-00 1 325 1
1A 325 1
1B 325 1
5 - 1 RF
5507-2-10 1A 330 1
5 - 1A RF
5507-2-20 1 330 1
1A 330A 1
5 - 1B RF
5507-2-23 1 330A 1
1A 330B 1
5 - 1C RF
5507-3-20 1B 330 1
5 - 1D RF
5507-4-10 1A 330C 1
5 - 1E RF
5507-4-20 1 330B 1

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

1A 330D 1
5 - 1F RF
5507-4-23 1 330C 1
1A 330E 1
1B 330A 1
5 - 1G RF
5511-00 7 12 2
5513-00 7 - 15 1
5517-00 1 - 760 1
1A - 760 1
1B - 760 1
7 16 1
5518-00 7 - 17 1
5520-15 7 - 6 1
5520-16 7 6A 1
5522-00 1 - 765 1
1A - 765 1
1B - 765 1
7 20 1
5533-00 5 - 20 1
- 5 1
5533-01 5 12 1
55620-01 1 - 775 1
1A - 775 1
1B - 775 1
7 14A 1
55620-02 1 - 780 1
1A - 780 1
1B - 780 1
7 18A 1
5601-00 1B - 810 1
15 1
5602-00 1B - 10 1
5603-00 2 25 1
5606-00 2 26 1
5606-01 2 - 26B 1
5607-00 2 28A 1
5607-03 2 - 28 1
56750-00 9 5 1
56750-01 9 15 1
56750-02 9 15A 1
57524-00 7 - 23B 1
58532-00 7 54B 1
59447-00 3 2 1
59553-00 1 - 805 2
1A - 805 2
1B - 805 2

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

7 39A 2
59598-00 7 - 14 1
59602-00 1B 50 4
59776-01 7 - 54 1
6050-01 2 13 1
6050D 2 - 4 1
6055E 1B - 830 1
2 20 1
6066-00 2 - 23 2
6066-01 1B - 820 2
2 23A 2
6084-01 1 - 515 1
- 515C 1
6084-02 1 - 515A 1
6084-20 1 - 515B 1
- 515D 1
1B - 515A 1
515 1
6131-00 2 - 29 1
614010 5 - 9 1
6350A13XA 1 - 500 1
- 500C 1
6350A14XA 1 500A 1
6350A20XA 1 - 500D 1
500B 1
1B - 500 1
- 500A 1
6370-00 1 - 770 1
1A - 770 1
1B - 770 1
7 - 34 1
6375-05 2 8 1
6378-00 2 11 1
6555-00 7 32 1
6582-00 2 14 1
6583-00 2 12C 1
6584-00 2 12D 1
6586-00 2 12A 1
6588-00 2 12B 1
6597-00 2 9 1
6812-00 1B - 850 1
2 27 1
7171-00 7 29 1
800409-00 10 12 1
800651-00 2 - 5 1
801160-00 1 - 400 1
7 - 1 RF

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

801160-01 1 - 405 1
1B - 400 1
7 - 1A RF
801160-02 1 - 410 1
1B - 405 1
7 - 2A RF
801160-03 1 400A 1
405A 1
1B 400A 1
7 - 2 RF
801160-04 1 410A 1
1B 405A 1
7 - 3 RF
801242-01 1B 30 1
2 - 1 RF
801242-02 1B - 35 1
2 - 2 RF
801242-03 1B - 40 1
2 - 2A RF
801242-04 1B - 45 1
2 - 3 RF
801421-00 7 - 26 1
801421-01 7 - 27 1
801658-00 1 - 105 1
1B - 105 1
801659-00 1 110 1
1B - 110 1
801660-00 1 100 1
10 8 1
1A 100 1
1B 100 1
1C 100 1
801661-00 1 115 1
1B - 115 1
801663-01 1 130 1
801809-01 1 140 1
10 4 1
801821-21 7 - 36A 1
802821-01 7 36B 1
9 - 1G RF
802821-21 9 - 1F RF
802856-01 1 340 1
1B 340 1
8 - 1 RF
802883-01 1 - 800 1
1A - 800 1
1B - 800 1

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

7 17A 1
803129-01 1 - 795 1
1A - 795 1
1B - 795 1
7 49A 1
803177-01 10 - 3 1
803199-04 1A 415 1
7 - 4 RF
803199-05 1A - 420 1
7 - 5 RF
803668-01 10 1 RF
804201-01 5 30 1
6A 1
804202-01 7 21A 1
804329-01 4 - 10A 1
- 20 1
804376-01 3 - 6A 1
804620-01 9 - 7 1
804670-03 7 - 9B 1
805118-01 1 - 125 1
805984-07 1C 505 1
807433-01 1C 415 1
7 - 5A RF
807433-02 1C - 415A 1
7 - 5B RF
807434-01 1C - 1 RF
807803-01 7 58A 1
807803-02 7 59A 1
807803-05 7 60A 1
807803-06 7 61A 1
832100 5 - 7 1
832402 5 - 8 1
833012 5 - 11 1
8384-00 7 - 25 1
8385-00 7 - 24 1
8561-00 7 - 42 1
8561-02 7 42A 1
9036-00 2 - 19 2
9700A1AB20A 1 - 1C RF
9700A1ABF20B 1 - 1 RF
9700A1ABF23A 1 - 1A RF
9700A1ABF23B 1 - 1B RF
9700A1AYY0N 1 - 1D RF
9700B1XBBF25A 1 - 1E RF
10 - 2 1
9700C1AB23AN 1 - 1Q RF
9700C1ABB23A 1 - 1F RF

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

9700C1ABF20A 1 - 1G RF
9700C1ABF20B 1 - 1H RF
9700C1ABF20D 1 - 1J RF
9700C1ABF23A 1 - 1K RF
9700C1ABF23AM 1 - 1L RF
9700C1ABF23AN 1 - 2M RF
9700C1ABF23B 1 - 1M RF
9700C1ABF23C 1 - 1N RF
9700C1ABF23D 1 - 1P RF
9700C1AF20D 1 - 1R RF
9700C1AF23A 1 - 1S RF
9700C1AF23AM 1 - 1T RF
9700C1AF23AN 1 - 1U RF
9700C1AF23BN 1 - 1V RF
9700C1AFF23A 1 - 2K RF
9700C1AY0N 1 - 1Y RF
9700C1AYY0N 1 - 1W RF
9700C1AYY0S 1 - 1X RF
9700C1BBF23D 1 - 1Z RF
9700C1CBF23A 1 - 2 RF
9700C2CF20D 1 - 2A RF
9700C3CBF20D 1 - 2B RF
9700D1ABBF20B 1 - 2C RF
9700D1ABBF23A 1 - 2D RF
9700F1ABF23AM 1 - 2E RF
9700F1ABF23AN 1 - 2F RF
9700F1ABF23BN 1 - 2G RF
9700F1ABY23AN 1 - 2H RF
9700F1AF23AKN 1 - 2L RF
9700F1AYYY0N 1 - 2J RF
9700G2ABF10A 1A - 1 RF
9700G2ABF10B 1A - 1A RF
9700G2ABF10D 1A - 1B RF
9700G2ABF20A 1A - 1C RF
9700G2ABF20B 1A - 1D RF
9700G2ABF20D 1A - 1E RF
9700G2ABF23A 1A - 1F RF
9700G2ABF23B 1A - 1G RF
9700G2ABF23D 1A - 1H RF
9700G2ABF25A 1A - 1T RF
9700G2AF10AN 1A - 1J RF
9700G2AF10D 1A - 1K RF
9700G2AF20AN 1A - 1L RF
9700G2AF20D 1A - 1M RF
9700G2AF23AN 1A - 1N RF
9700G2AF23D 1A - 1P RF
9700G2AFF25B 1A - 1U RF

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

9700G2XY0N 1A - 1V RF
9700H2ABF10BN 1A - 1Q RF
9700H2ABF20BN 1A - 1R RF
9700H2ABF23BN 1A - 1S RF
98001C1AE20A 1B - 1 RF
98001C1AE20B 1B - 1A RF
98001C1AE23B 1B - 1B RF
98001C1AF20A 1B - 1C RF
98001C1AF20B 1B - 1D RF
98001C1AF23A 1B - 1E RF
98001C1AX0N 1B - 1F RF
98001C1AX0X 1B - 1G RF
98001D1ABF23A 1B - 1H RF
98001D1AF23AM 1B - 2E RF
98001D1AF23AN 1B - 1J RF
98002C1AE20A 1B - 1K RF
98002C1AE20B 1B - 1L RF
98002C1AE20C 1B - 1M RF
98002C1AE20D 1B - 1N RF
98002C1AE23A 1B - 1P RF
98002C1AE23B 1B - 1Q RF
98002C1AF23A 1B - 1R RF
98002C1AF23D 1B - 1S RF
98002C1AX0M 1B - 1T RF
98002C1AX0X 1B - 1U RF
98002D1ABF20B 1B - 1V RF
98002D1ABF23A 1B - 1W RF
98002D1AE23AM 1B - 1X RF
98002D1AF20BM 1B - 1Y RF
98002D1AF23A 1B - 2G RF
98002D1AF23AM 1B - 1Z RF
98002D1AF23AN 1B - 2 RF
98002D1AF23BM 1B - 2A RF
98002D1AF23BN 1B - 2H RF
98002D1AF23DM 1B - 2J RF
98008C1BF23A 1B - 2F RF
98009C1AE23A 1B - 2B RF
98009C1AF23AM 1B - 2K RF
98009C1AX0X 1B - 2C RF
98009D1AF23AM 1B - 2D RF
A1120B 2 - 24 1
A1126 2 18 1
A1215-1 2 17 1
AD1983 2 - 26A 1
AN345C10 7 - 9 1
AN515-4-3 2 - 6 3
AN515-4-4 2 - 21 1

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
FIGURE ITEM TOTAL

AN936A4 2 - 22 1
AN960C10L 7 - 10 1
DPB 153 1 350 1
350A 2
350B 3
1A 350 1
DPB153 1B 350 1
EC9-5U 3 5 AR
4 8 AR
5 3 AR
6 3 AR
MS20470A2-2 2 10 2
12 2
MS21318-7 7 64 2
MS27769-2 1 - 365 1
1A - 365 1
1B - 365 1
MS27769S2 1 - 360 1
1A - 360 1
1B - 360 1
MS35206-212 2 7 3
MS35206-213 2 21A 2
MS35207-201 1B - 835 2
2 19A 2
MS35207-202 7 - 39 1
MS35333-36 1B - 845 2
2 22A 2
MS35650-304 7 - 9A 1
NAS1149C0332R 7 - 10A 1
NASM21083-C3 7 9C 1

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
DETAILED PARTS LIST
DPL 10001 Page 1

35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
9700-A, 9700-B, 9700-C, 9700-D, AND 9700-F SERIES PCA (Sheet 1 of 2)

Figure 1/35-31-55-991-801-A01
Page 10001-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
9700-A, 9700-B, 9700-C, 9700-D, AND 9700-F SERIES PCA (Sheet 2 of 2)

Figure 1/35-31-55-991-801-A01
Page 10001-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
AIRLINE NOMENCLATURE USAGE
FIG. ITEM PART NUMBER PER
PART No. CODE
1234567
ASSY
1
-1 9700A1ABF20B CYLINDER ASSY, PORTABLE A RF
(APN 9700-A1A-BF20B)
- 1A 9700A1ABF23A CYLINDER ASSY, PORTABLE B RF
(APN 9700-A1A-BF23A)
- 1B 9700A1ABF23B CYLINDER ASSY, PORTABLE C RF
(APN 9700-A1A-BF23B)
- 1C 9700A1AB20A CYLINDER ASSY, PORTABLE D RF
(APN 9700-A1A-B20A)
- 1D 9700A1AYY0N CYLINDER ASSY, PORTABLE E RF
(APN 9700-A1A-YY0N)
- 1E 9700B1XBBF25A CYLINDER ASSY, PORTABLE F RF
APN 9700-B1X-BBF25A)
- 1F 9700C1ABB23A CYLINDER ASSY, PORTABLE G RF
(APN 9700-C1A-BB23A)
- 1G 9700C1ABF20A CYLINDER ASSY, PORTABLE H RF
(APN 9700-C1A-BF20A)
- 1H 9700C1ABF20B CYLINDER ASSY, PORTABLE J RF
(APN 9700-C1A-BF20B)
- 1J 9700C1ABF20D CYLINDER ASSY, PORTABLE K RF
(APN 9700-C1A-BF20D)
- 1K 9700C1ABF23A CYLINDER ASSY, PORTABLE L RF
(APN 9700-C1A-BF23A)
- 1L 9700C1ABF23AM CYLINDER ASSY, PORTABLE M RF
(APN 9700-C1A-BF23AM)
- 1M 9700C1ABF23B CYLINDER ASSY, PORTABLE N RF
(APN 9700-C1A-BF23B)
- 1N 9700C1ABF23C *** DELETED ***
- 1P 9700C1ABF23D CYLINDER ASSY, PORTABLE Q RF
(APN 9700-C1A-BF23D)
- 1Q 9700C1AB23AN CYLINDER ASSY, PORTABLE R RF
(APN 9700-C1A-B23AN)
- 1R 9700C1AF20D CYLINDER ASSY, PORTABLE S RF
(APN 9700-C1A-F20D)
- 1S 9700C1AF23A CYLINDER ASSY, PORTABLE T RF
(APN 9700-C1A-F23A)
- 1T 9700C1AF23AM CYLINDER ASSY, PORTABLE U RF
(APN 9700-C1A-F23AM)
- 1U 9700C1AF23AN CYLINDER ASSY, PORTABLE V RF
(APN 9700-C1A-F23AN)
- 1V 9700C1AF23BN CYLINDER ASSY, PORTABLE W RF
(APN 9700-C1A-F23BN)
- 1W 9700C1AYY0N CYLINDER ASSY, PORTABLE X RF
(APN 9700-C1A-YY0N)
- 1X 9700C1AYY0S CYLINDER ASSY, PORTABLE Y RF
(APN 9700-C1A-YY0S)
- 1Y 9700C1AY0N CYLINDER ASSY, PORTABLE Z RF
(APN 9700-C1A-Y0N)
- ITEM NOT ILLUSTRATED
Page 10001-2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1
- 1Z 9700C1BBF23D CYLINDER ASSY, PORTABLE BA RF
(APN 9700-C1B-BF23D)
-2 9700C1CBF23A CYLINDER ASSY, PORTABLE CA RF
(APN 9700-C1C-BF23A)
- 2A 9700C2CF20D CYLINDER ASSY, PORTABLE DA RF
(APN 9700-C2C-F20D)
- 2B 9700C3CBF20D CYLINDER ASSY, PORTABLE EA RF
(APN 9700-C3C-BF20D)
- 2C 9700D1ABBF20B CYLINDER ASSY, PORTABLE FA RF
(APN 9700-D1A-BBF20B)
- 2D 9700D1ABBF23A CYLINDER ASSY, PORTABLE GA RF
(APN 9700-D1A-BBF23A)
- 2E 9700F1ABF23AM CYLINDER ASSY, PORTABLE HA RF
(APN 9700-F1A-BF23AM)
- 2F 9700F1ABF23AN CYLINDER ASSY, PORTABLE JA RF
(APN 9700-F1A-BF23AN)
- 2G 9700F1ABF23BN CYLINDER ASSY, PORTABLE KA RF
(APN 9700-F1A-BF23BN)
- 2H 9700F1ABY23AN CYLINDER ASSY, PORTABLE LA RF
(APN 9700-F1A-BY23AN)
- 2J 9700F1AYYY0N CYLINDER ASSY, PORTABLE MA RF
(APN 9700-F1A-YYY0N)
- 2K 9700C1AFF23A CYLINDER ASSY, PORTABLE NA RF
(APN 9700-C1A-FF23A)
- 2L 9700F1AF23AKN CYLINDER ASSY, PORTABLE PA RF
(APN 9700-F1A-F23AKN)
- 2M 9700C1ABF23AN CYLINDER ASSY, PORTABLE QA RF
(APN 9700-C1A-BF23AN)
60 13160-00 . CLAMP 1
ALT TO WWD-120 (53655)
100 801660-00 . HARNESS A-E, 1
G-Z,
FA-QA
- 105 801658-00 . HARNESS (STRAP ASSY) BA 1
110 801659-00 .. STRAP ASSY NP BA 1
115 801661-00 .. STRAP ASSY NP BA 1
120 13160-00 *** DELETED ***
- 125 805118-01 . HARNESS, ASSY WITH MASK CA-EA 1
AND STORAGE BAG
130 801663-01 .. STRAP ASSY CA-EA 1
135 13160-00 .. CLAMP CA-EA 1
140 801809-01 .. BAG ASSY, MASK STORAGE CA-EA 1
145 36879-01 .. FASTENER, VELSTRAP, HOOK CA-EA 1
AND LOOP
Page 10001-3
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1
150 289-601-214 .. MASK ASSY, PASSENGER CA-EA 1
OXYGEN
RPLD BY ITEM 150A
(REFER TO CMM 35-22-26
FOR DET BKDN)
- 150A 289-601-434 .. MASK ASSY, PASSENGER CA-EA 1
OXYGEN
RPLS ITEM -150
(REFER TO CMM 35-22-26
FOR DET BKDN)
155 14807-00 *** DELETED ***
- 200 10002542 . DECAL, OPERATOR A-CA, 1
INSTRUCTION FA-PA
RPLD BY ITEM 205
205 10009072 . DECAL, OPERATOR A-CA, 1
INSTRUCTION FA-QA
RPLS ITEM -200
- 210 10005927 . DECAL, OXYGEN I.D. 1
RPLD BY ITEM 215
215 10009255 . DECAL, OXYGEN I.D. 1
RPLS ITEM -210
220 10002538 . PLATE, IDENTIFICATION G-EA, 1
HA-QA
- 225 10003202 . PLATE, IDENTIFICATION A-E, FA, 1
GA
- 230 10010748 . PLACARD, BOTTLE INSPECTION DA, EA 1
- 235 10010747 . PLACARD, OPERATING DA 1
INSTRUCTION
(9700-X2X SERIES W/ 1
OUTLET ONLY)
- 240 10010859 . PLACARD, OPERATING EA 1
INSTRUCTION
(9700-X3X SERIES W/ 2
OUTLETS ONLY)
300 5009-00 *** DELETED ***
305 5009-2-20 . OUTLET ASSY D, H 1
(REFER TO FIG 3 FOR DET BKDN)
305A 5009-2-23 . OUTLET ASSY B, L, M, 1
(REFER TO FIG 3 FOR DET BKDN) R, CA,
HA, JA,
LA, QA
305B 5009-2-23 . OUTLET ASSY G, GA 2
305C 5009-2-25 . OUTLET ASSY F 2
Page 10001-4
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1
305D 5009-2-25 *** DELETED ***
305E 5009-4-20 . OUTLET ASSY H 1
305F 5009-4-23 . OUTLET ASSY B, L, M, 1
(REFER TO FIG 3 FOR DET BKDN) T-V, CA,
GA, HA,
JA, PA,
QA
305G 5009-4-25 . OUTLET ASSY F 1
305H 5009-4-23 . OUTLET ASSY NA 2
310 5041-00 *** DELETED ***
315 5041-2-20 . OUTLET ASSY A, J 1
315A 5041-2-20 . OUTLET ASSY FA 2
315B 5041-2-23 . OUTLET ASSY C, N, KA 1
315C 5041-4-20 . OUTLET ASSY A, J, FA 1
315D 5041-4-23 . OUTLET ASSY C, N, W, 1
(REFER TO FIG 4 FOR DET BKDN) KA
320 5052-00 *** DELETED ***
320A 5052-00 *** DELETED ***
325 5507-00 *** DELETED ***
330 5507-2-20 . OUTLET ASSY K, EA 1
330A 5507-2-23 . OUTLET ASSY Q, BA 1
330B 5507-4-20 . OUTLET ASSY K, S, DA, 1
(REFER TO FIG 5 FOR DET BKDN) EA
330C 5507-4-23 . OUTLET ASSY Q, BA 1
335 10003566 . OUTLET ASSY HA 1
RPLD BY ITEM -340
340 802856-01 . OUTLET ASSY M, U, HA 1
[SIMILAR TO PURITAN BENNETT
(V49315) PN 110111 -09]
RPLS ITEM -335
345 10008298 . OUTLET ASSY Y 2
345A 10008298 *** DELETED ***
350 DPB 153 . OUTLET ASSY NP E, R, V, 1
RPLD BY ITEM -355 W, Z,
JA-LA,
PA, QA
Page 10001-5
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1
350A DPB 153 . OUTLET ASSY NP X 2
RPLD BY ITEM -355A
350B DPB 153 . OUTLET ASSY NP MA 3
RPLD BY ITEM -355B
355 36728-01 . OUTLET ASSY R, V, 1
RPLS ITEM -350 W, Z,
JA-LA,
PA, QA
355A 36728-01 . OUTLET ASSY E, X 2
RPLS ITEM -350A
355B 36728-01 . OUTLET ASSY MA 3
RPLS ITEM -350B
- 360 MS27769S2 . PLUG, PIPE (CRES) (0.125 – 96906 D, S, T, 1
27 ANPT THD) Z, DA,
(APN 6818-01) HA-LA,
RPLS ITEM -365 PA
- 365 MS27769-2 . PLUG, PIPE (CAD PLATED STEEL) 96906 D, S, T, 1
(APN 6818-00) Z, DA,
RPLD BY ITEM -360 HA-LA
- 400 801160-00 . REGULATOR ASSY (2 OUTLET NP A-E 1
PORTS)
RPLD BY ITEM 400A
(REFER TO FIG 7 FOR BKDN)
400A 801160-03 . REGULATOR ASSY (2 OUTLET A-E, 1
PORTS) G-EA,
RPLS ITEM -400 NA, QA
- 405 801160-01 . REGULATOR ASSY (2 OUTLET NP G-EA, 1
PORTS) NA, QA
RPLD BY ITEM -400A
405A 801160-03 *** DELETED ***
- 410 801160-02 . REGULATOR ASSY (3 OUTLET NP FA-MA, 1
PORTS) PA
RPLD BY ITEM 410A
410A 801160-04 . REGULATOR ASSY (3 OUTLET F, 1
PORTS) FA-MA,
RPLS ITEM -410 PA
- 500 6350A13XA . CYLINDER, LW A-E, FA, 1
(TRUE PN 6350A13-X-A) GA
RPLS ITEM 515
(POST SB 6084-00-35-01)
Page 10001-6
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1
500A 6350A14XA . CYLINDER, LW F 1
(TRUE PN 6350A14-X-A)
RPLS ITEM 515A
(POST SB 6084-00-35-01)
500B 6350A20XA . CYLINDER, LW G-EA, 1
(TRUE PN 6350A20-X-A) HA-QA
RPLS ITEM 515B
(POST SB 6084-00-35-01)
- 500C 6350A13XA *** DELETED ***
- 500D 6350A20XA *** DELETED ***
- 515 6084-01 . CYLINDER, STEEL (DOT-3AA- NP A-E, FA, 1
1800) (4.25 CU FT, UNPAINTED) GA
(PRE SB 6084-00-35-01)
RPLD BY ITEM 500
- 515A 6084-02 . CYLINDER, STEEL (DOT-3AA- NP F 1
1800) (7.15 CU FT, UNPAINTED)
(PRE SB 6084-00-35-01)
RPLD BY ITEM 500A
- 515B 6084-20 . CYLINDER, STEEL (DOT-3AA- NP G-EA, 1
1800) (11 CU FT, UNPAINTED) HA-QA
(PRE SB 6084-00-35-01)
RPLD BY ITEM 500B
- 515C 6084-01 *** DELETED ***
- 515D 6084-20 *** DELETED ***
- 750 28022-00 . OVERHAUL KIT FOR THE 9700 1
SERIES REGULATOR
- 755 5032-01 .. DIAPHRAGM 1
- 760 5517-00 .. SEAT, TEFLON 1
- 765 5522-00 .. FILTER 1
- 770 6370-00 .. WASHER NP 1
RPLD BY ITEM -770A
- 770A 10015704 .. GASKET, SEAL 1
RPLS ITEM -770
- 775 55620-01 .. PACKING, PREFORMED 1
- 785 5056-00 .. PLATE, IDENTIFICATION 1
- 795 803129-01 .. SEAT ASSY, VALVE 1
- 800 802883-01 .. HEAD ASSY, VALVE 1
- 805 59553-00 *** DELETED ***
- 810 32008-02 *** DELETED ***
- 810A 37008-02 .. SCREW SET-LOCK OVAL POINT 1
Page 10001-7
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
9700-G2A AND 9700-H2A SERIES PCA

Figure 1A/GRAPHIC-35-31-55-991-175-A01
Page 10001A-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1A
-1 9700G2ABF10A CYLINDER ASSY, PORTABLE A RF
(APN 9700-G2A-BF10A)
- 1A 9700G2ABF10B CYLINDER ASSY, PORTABLE B RF
(APN 9700-G2A-BF10B)
- 1B 9700G2ABF10D CYLINDER ASSY, PORTABLE C RF
(APN 9700-G2A-BF10D)
- 1C 9700G2ABF20A CYLINDER ASSY, PORTABLE D RF
- 1D 9700G2ABF20B CYLINDER ASSY, PORTABLE E RF
- 1E 9700G2ABF20D CYLINDER ASSY, PORTABLE F RF
- 1F 9700G2ABF23A CYLINDER ASSY, PORTABLE G RF
- 1G 9700G2ABF23B CYLINDER ASSY, PORTABLE H RF
- 1H 9700G2ABF23D CYLINDER ASSY, PORTABLE J RF
- 1J 9700G2AF10AN CYLINDER ASSY, PORTABLE K RF
(APN 9700-G2A-F10AN)
- 1K 9700G2AF10D CYLINDER ASSY, PORTABLE L RF
(APN 9700-G2A-F10D)
- 1L 9700G2AF20AN CYLINDER ASSY, PORTABLE M RF
- 1M 9700G2AF20D CYLINDER ASSY, PORTABLE N RF
(APN 9700-G2A-F20D)
- 1N 9700G2AF23AN CYLINDER ASSY, PORTABLE P RF
- 1P 9700G2AF23D CYLINDER ASSY, PORTABLE Q RF
(APN 9700-G2A-F23D)
- 1Q 9700H2ABF10BN CYLINDER ASSY, PORTABLE R RF
(APN 9700-H2A-BF10BN)
- 1R 9700H2ABF20BN CYLINDER ASSY, PORTABLE S RF
- 1S 9700H2ABF23BN CYLINDER ASSY, PORTABLE T RF
- 1T 9700G2ABF25A CYLINDER ASSY, PORTABLE U RF
- 1U 9700G2AFF25B CYLINDER ASSY, PORTABLE V RF
(APN 9700-G2A-FF25B)
- 1V 9700G2XY0N CYLINDER ASSY, PORTABLE W RF
(APN 9700-G2X-Y0N)
60 13160-00 . CLAMP 1
ALT TO WWD-120 (53655)
100 801660-00 . HARNESS A-V 1
205 10009072 . DECAL, OPERATOR 1
INSTRUCTION
Page 10001A-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1A
- 210 10005927 . DECAL, OXYGEN I.D. 1
RPLD BY ITEM 215
215 10009255 . DECAL, OXYGEN I.D. 1
RPLS ITEM -210
220 10008980 . PLATE, IDENTIFICATION 1
- 245 10006442 . DECAL, WARNING 1
300 5009-00 *** DELETED ***
305 5009-2-10 . OUTLET ASSY A 1
305A 5009-2-20 . OUTLET ASSY D 1
305B 5009-2-23 . OUTLET ASSY G 1
305C 5009-4-10 . OUTLET ASSY A, K 1
305D 5009-4-20 . OUTLET ASSY D, M 1
305E 5009-4-23 . OUTLET ASSY G, P 1
305F 5009-2-25 . OUTLET ASSY U 1
305G 5009-4-25 . OUTLET ASSY U 1
310 5041-00 *** DELETED ***
315 5041-2-10 . OUTLET ASSY B, R 1
315A 5041-2-20 . OUTLET ASSY E, S 1
315B 5041-2-23 . OUTLET ASSY H, T 1
315C 5041-4-10 . OUTLET ASSY B, R 1
315D 5041-4-20 . OUTLET ASSY E, S 1
315E 5041-4-23 . OUTLET ASSY H, T 1
315F 5041-4-25 . OUTLET ASSY V 2
315G 5041-4-25 *** DELETED ***
325 5507-00 *** DELETED ***
330 5507-2-10 . OUTLET ASSY C 1
330A 5507-2-20 . OUTLET ASSY F 1
330B 5507-2-23 . OUTLET ASSY J 1
Page 10001A-2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1A
330C 5507-4-10 . OUTLET ASSY C, L 1
330D 5507-4-20 . OUTLET ASSY F, N 1
330E 5507-4-23 . OUTLET ASSY J, Q 1
350 DPB 153 . OUTLET ASSY NP K, M, P, 1
RPLD BY ITEM -355 R-T, W
355 36728-01 . OUTLET ASSY K, M, P, 1
RPLS ITEM -350 R-T, W
(REFER TO FIG 14 FOR
DET BKDN)
- 360 MS27769S2 . PLUG, PIPE (CRES) (0.125 – 96906 L, N, 1
27 ANPT THD) Q-T, W
(APN 6818-01)
RPLS ITEM -365
- 365 MS27769-2 . PLUG, PIPE (CAD PLATED STEEL) 96906 L, N, 1
(APN 6818-00) Q-T
RPLD BY ITEM 360
415 803199-04 . REGULATOR ASSY (2 OUTLET A-Q, 1
PORTS) U-W
- 420 803199-05 . REGULATOR ASSY (3 OUTLET R-T 1
PORTS)
505 21507-06 . CYLINDER, COMPOSITE 1
(DOT-SP-8162-1850) (11 CU
FT) [ PAINTED GREEN 14187]
- 510 21507-06 *** DELETED ***
SERIES REGULATOR
- 755 5032-01 .. DIAPHRAGM 1
- 760 5517-00 .. SEAT, TEFLON 1
- 765 5522-00 .. FILTER 1
- 770 6370-00 .. WASHER 1
RPLD BY ITEM -770A
- 770A 10015704 .. GASKET, SEAL 1
RPLS ITEM -770
- 795 803129-01 .. SEAT ASSY, VALVE 1
- 800 802883-01 .. HEAD ASSY, VALVE 1
- 805 59553-00 *** DELETED ***
- 810 37008-02 .. SCREW SET-LOCK OVAL POINT 1
Page 10001A-3
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
9800 SERIES PCA

Figure 1B/GRAPHIC-35-31-55-991-180-A01
Page 10001B-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1B
-1 98001C1AE20A CYLINDER ASSY, PORTABLE A RF
(APN 9800-1C1A-E20A)
- 1A 98001C1AE20B CYLINDER ASSY, PORTABLE B RF
(APN 9800-1C1A-E20B)
- 1B 98001C1AE23B CYLINDER ASSY, PORTABLE C RF
(APN 9800-1C1A-E23B)
- 1C 98001C1AF20A CYLINDER ASSY, PORTABLE D RF
(APN 9800-1C1A-F20A)
- 1D 98001C1AF20B CYLINDER ASSY, PORTABLE E RF
(APN 9800-1C1A-F20B)
- 1E 98001C1AF23A CYLINDER ASSY, PORTABLE F RF
(APN 9800-1C1A-F23A)
- 1F 98001C1AX0N CYLINDER ASSY, PORTABLE G RF
(APN 9800-1C1A-X0N)
- 1G 98001C1AX0X CYLINDER ASSY, PORTABLE H RF
(APN 9800-1C1A-X0X)
- 1H 98001D1ABF23A CYLINDER ASSY, PORTABLE J RF
(APN 9800-1D1A-BF23A)
- 1J 98001D1AF23AN CYLINDER ASSY, PORTABLE K RF
(APN 9800-1D1A-F23AN)
- 1K 98002C1AE20A CYLINDER ASSY, PORTABLE L RF
(APN 9800-2C1A-E20A)
- 1L 98002C1AE20B CYLINDER ASSY, PORTABLE M RF
(APN 9800-2C1A-E20B)
- 1M 98002C1AE20C *** DELETED ***
- 1N 98002C1AE20D CYLINDER ASSY, PORTABLE P RF
(APN 9800-2C1A-E20D)
- 1P 98002C1AE23A CYLINDER ASSY, PORTABLE Q RF
(APN 9800-2C1A-E23A)
- 1Q 98002C1AE23B CYLINDER ASSY, PORTABLE R RF
(APN 9800-2C1A-E23B)
- 1R 98002C1AF23A CYLINDER ASSY, PORTABLE S RF
(APN 9800-2C1A-F23A)
- 1S 98002C1AF23D CYLINDER ASSY, PORTABLE T RF
(APN 9800-2C1A-F23D)
- 1T 98002C1AX0M CYLINDER ASSY, PORTABLE U RF
(APN 9800-2C1A-X0M)
- 1U 98002C1AX0X CYLINDER ASSY, PORTABLE V RF
(APN 9800-2C1A-X0X)
- 1V 98002D1ABF20B CYLINDER ASSY, PORTABLE W RF
(APN 9800-2D1A-BF20B)
- 1W 98002D1ABF23A CYLINDER ASSY, PORTABLE X RF
(APN 9800-2D1A-BF23A)
- 1X 98002D1AE23AM CYLINDER ASSY, PORTABLE Y RF
(APN 9800-2D1A-E23AM)
- 1Y 98002D1AF20BM CYLINDER ASSY, PORTABLE Z RF
(APN 9800-2D1A-F20BM)
Page 10001B-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1B
- 1Z 98002D1AF23AM CYLINDER ASSY, PORTABLE BA RF
(APN 9800-2D1A-F23AM)
-2 98002D1AF23AN CYLINDER ASSY, PORTABLE CA RF
(APN 9800-2D1A-F23AN)
- 2A 98002D1AF23BM CYLINDER ASSY, PORTABLE DA RF
(APN 9800-2D1A-F23BM)
- 2B 98009C1AE23A CYLINDER ASSY, PORTABLE EA RF
(APN 9800-9C1A-E23A)
- 2C 98009C1AX0X CYLINDER ASSY, PORTABLE FA RF
(APN 9800-9C1A-X0X)
- 2D 98009D1AF23AM CYLINDER ASSY, PORTABLE GA RF
(APN 9800-9D1A-F23AM)
- 2E 98001D1AF23AM CYLINDER ASSY, PORTABLE HA RF
(APN 9800-1D1A-F23AM)
- 2F 98008C1BF23A CYLINDER ASSY, PORTABLE JA RF
(APN 9800-8C1B-F23A)
- 2G 98002D1AF23A CYLINDER ASSY, PORTABLE KA RF
(APN 9800-2D1A-F23A)
- 2H 98002D1AF23BN CYLINDER ASSY, PORTABLE LA RF
(APN 9800-2D1A-F23BN)
- 2J 98002D1AF23DM CYLINDER ASSY, PORTABLE MA RF
(APN 9800-2D1A-F23DM)
- 2K 98009C1AF23AM CYLINDER ASSY, PORTABLE NA RF
(APN 9800-9C1A-F23AM)
- 10 5602-00 . CONNECTOR ASSY 1
RPLD BY ITEM 10A
10A 33529-009 . CONNECTOR , TUBE (ALUMINUM) 1
RPLS ITEM -10
15 5601-00 . ELBOW ASSY 1
30 801242-01 . REGULATOR, DEMAND A-K, HA 1
RESPIRATOR
- 35 801242-02 . REGULATOR, DEMAND L-DA, 1
RESPIRATOR KA-MA
- 40 801242-03 . REGULATOR, DEMAND JA 1
RESPIRATOR
- 45 801242-04 . REGULATOR, DEMAND EA-GA, 1
RESPIRATOR NA
ATTACHING PARTS
50 59602-00 . MACHINE SCREW, W / NYLOK 4
INSERT (.164-32 UNC-2A X .250)
* * *
55 10001296 . BRACKET 1
Page 10001B-2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1B
60 13160-00 . CLAMP 2
ALT TO WWD-120 (53655)
- 75 13160-00 *** DELETED ***
100 801660-00 . HARNESS A-HA, 1
KA-NA
- 105 801658-00 . HARNESS JA 1
- 110 801659-00 .. STRAP ASSY NP JA 1
- 115 801661-00 .. STRAP ASSY NP JA 1
- 120 13160-00 *** DELETED ***
- 200 10002543 . DECAL, INSTRUCTION 1
RPLD BY ITEM 205
205 10009071 . DECAL, INSTRUCTION 1
RPLS ITEM -200
- 210 10005927 . DECAL, OXYGEN I.D. 1
RPLD BY ITEM 215
215 10009255 . DECAL, OXYGEN I.D. 1
RPLS ITEM -210
300 5009-00 *** DELETED ***
305 5009-2-23 . OUTLET ASSY J, X 1
305A 5009-3-20 . OUTLET ASSY A, L 1
305B 5009-3-23 . OUTLET ASSY Q, Y, EA 1
305C 5009-4-20 . OUTLET ASSY D 1
305D 5009-4-23 . OUTLET ASSY F, J, K, 1
(REFER TO FIG 3 FOR DET BKDN) S, X,
BA, CA,
GA-KA,
NA
310 5041-00 *** DELETED ***
315 5041-2-20 . OUTLET ASSY W 1
315A 5041-3-20 . OUTLET ASSY B, M 1
315B 5041-3-23 . OUTLET ASSY C, R 1
315C 5041-4-20 . OUTLET ASSY E, W, Z 1
315D 5041-4-23 . OUTLET ASSY DA, LA 1
Page 10001B-3
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1B
320 5052-00 *** DELETED ***
320A 5052-00 *** DELETED ***
325 5507-00 *** DELETED ***
330 5507-3-20 . OUTLET ASSY P 1
330A 5507-4-23 . OUTLET ASSY T, MA 1
335 10003566 . OUTLET ASSY NP U, Y, Z, 1
RPLD BY ITEM -340 BA, DA,
GA, HA
340 802856-01 . OUTLET ASSY 49315 U, Y, Z, 1
(REFER TO FIG 8 FOR DET BKDN) BA, DA,
[SIMILAR TO PURITAN BENNETT GA, HA,
(V49315) PN 110111 -09] MA, NA
RPLS ITEM -335
350 DPB153 . OUTLET ASSY G, K, 1
RPLD BY ITEM -355 CA, LA
355 36728-01 . OUTLET ASSY G, K, 1
RPLS ITEM -350 CA, LA
- 360 MS27769S2 . PLUG, PIPE (CRES) (0.125 – 96906 H, V, FA 1
27 ANPT THD)
(APN 6818-01)
RPLS ITEM -365
- 365 MS27769-2 . PLUG, PIPE (CAD PLATED STEEL) 96906 H, V, FA 1
(0.125 – 27 ANPT THD)
(APN 6818-00)
RPLD BY ITEM -360
- 400 801160-01 . REGULATOR ASSY (2 OUTLET NP A-H, L-V, 1
PORTS) EA, FA,
RPLD BY ITEM 400A JA, NA
400A 801160-03 . REGULATOR ASSY (2 OUTLET A-H, L-V, 1
PORTS) EA, FA,
RPLS ITEM -400 JA, NA
- 405 801160-02 . REGULATOR ASSY (3 OUTLET NP J, K, 1
PORTS) W-DA,
RPLD BY ITEM 405A GA, HA,
(REFER TO FIG 7 FOR BKDN) KA-MA
405A 801160-04 . REGULATOR ASSY (3 OUTLET J, K, 1
PORTS) W-DA,
RPLS ITEM -405 GA, HA,
(REFER TO FIG 7 FOR BKDN) KA-MA
- 500 6350A20XA . CYLINDER, LW 1
(TRUE PN 6350A20-X-A)
RPLS ITEM 515
(POST SB 6084-00-35-01)
Page 10001B-4
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1B
- 500A 6350A20XA *** DELETED ***
515 6084-20 . CYLINDER, STEEL (DOT-3AA- NP 1
1800) (11 CU FT, UNPAINTED)
(PRE SB 6084-00-35-01)
RPLD BY ITEM 500
- 515A 6084-20 *** DELETED ***
SERIES REGULATOR
- 755 5032-01 .. DIAPHRAGM 1
- 760 5517-00 .. SEAT, TEFLON 1
- 765 5522-00 .. FILTER 1
- 770 6370-00 .. WASHER, SAFETY PLUG (FIBER) 1
RPLD BY ITEM -770A
- 770A 10015704 .. GASKET, SEAL 1
RPLS ITEM -770
- 795 803129-01 .. SEAT ASSY, VALVE 1
- 800 802883-01 .. HEAD ASSY, VALVE 1
- 805 59553-00 *** DELETED ***
- 810 5601-00 .. ELBOW ASSY 1
- 815 33529-009 .. CONNECTOR, TUBE (ALUMINUM) 1
- 820 6066-01 .. WASHER, FLAT (CRES) (0.281 IN. 2
OD X 0.125 IN. ID X 0.031 IN. THK)
- 825 13374-00 .. DIAPHRAGM ASSY 1
- 830 6055E .. VALVE ASSY, DEMAND 1
- 835 MS35207-201 .. SCREW, PAN HEAD (CAD 96906 2
PLATED STEEL) (#2-64 THD
X 0.125 IN. LNG)
(APN 33326-201)
- 840 13362-00 .. GASKET, DEMAND VALVE SEAT 1
- 845 MS35333-36 .. WASHER, LOCK (CAD PLATED 96906 2
STEEL) (#4 DIA X 0.017 IN. THK)
(APN 33460-036)
- 850 6812-00 .. SCREEN, REGULATOR INLET 1
(BRASS)
- 855 37008-02 .. SCREW SET, LOCKING, 1
OVAL POINT
- 860 33321-213 .. SCREW, PAN HEAD 2
Page 10001B-5
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
807434 Series PCA

Figure 1C/GRAPHIC-35-31-55-991-185-A01
Page 10001C-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
1C
-1 807434-01 CYLINDER ASSY, PORTABLE RF
ATTACHING PARTS
60 13160-00 . CLAMP 1
* * *
100 801660-00 . STRAP, SLING 1
215 10009255 . DECAL, OXYGEN I.D. 1
245 10008459 . DECAL, WARNING 1
415 807433-01 . REGULATOR ASSY (2 OUTLET 1
PORTS)
RPLD BY ITEM -415A
REFER TO FIG 7 FOR DET BKDN
- 415A 807433-02 . REGULATOR ASSY (2 OUTLET 1
PORTS)
RPLS ITEM -415
REFER TO FIG 7 FOR DET BKDN
505 805984-07 . CYLINDER, COMPOSITE 1
(DOT-SP-10915-1850) 7 CU
FT) [ PAINTED GREEN 14090
PER FED STD 595]
Page 10001C-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
801242-01, -02, -03, and -04 Respirator Regulator Assembly

Figure 2/GRAPHIC-35-31-55-991-190-A01
Page 10002-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
2
-1 801242-01 REGULATOR ASSY, RESPIRATOR A RF
(DEMAND TYPE)
(REFER TO FIG 1B FOR NHA)
-2 801242-02 . REGULATOR ASSY, RESPIRATOR B RF
- 2A 801242-03 . REGULATOR ASSY, RESPIRATOR C RF
(DEMAND/PRESSURE-DEMAND
TYPE)
-3 801242-04 . REGULATOR ASSY, RESPIRATOR D RF
(DEMAND/PRESSURE-DEMAND
TYPE)
-4 6050D . COVER ASSY A, B 1
(APN 59711-00)
-5 800651-00 . COVER ASSY C, D 1
ATTACHING PARTS
-6 AN515-4-3 . SCREW, PAN HEAD 3
RPLD BY ITEM 7
7 MS35206-212 . SCREW, PAN HEAD (CAD 96906 3
X 0.188 IN. LNG)
(APN 33321-212)
RPLS ITEM -6
* * *
8 6375-05 .. PLATE, IDENTIFICATION A, B 1
9 6597-00 .. PLATE, IDENTIFICATION C, D 1
ATTACHING PARTS
10 MS20470A2-2 .. RIVET (ALUMINUM) 96906 2
(APN 18415-00)
* * *
11 6378-00 .. PLATE, IDENTIFICATION A, B 1
ATTACHING PARTS
12 MS20470A2-2 .. RIVET (ALUMINUM) 96906 2
(APN 18415-00)
* * *
12A 6586-00 .. SPRING, COMPRESSION C, D 1
12B 6588-00 .. PLATE ASSY, W/ LEVER NP C, D 1
(ORDER NHA, ITEM -6)
12C 6583-00 .. SPRING 96906 C, D 1
12D 6584-00 .. BUTTON, SLIDE 96906 C, D 1
13 6050-01 .. COVER, CASE 96906 A, B 1
14 6582-00 .. COVER, CASE 96906 C, D 1
15 10007468 . PLATE, IDENTIFICATION 96906 C, D 1
16 13374-00 . DIAPHRAGM ASSY (ALT APN 96906 1
803145-01)
Page 10002-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
2
ATTACHING PARTS
17 A1215-1 . CORD, DIAPHRAGM (NYLON) NP 1
(APN A-1215-1)
RPLD BY ITEM 17A
17A 10009359 . CLAMP, DIAPHRAGM 96906 1
RPLS ITEM 17
* * *
18 A1126 . DEFLECTOR (APN A-1126)) 1
ATTACHING PARTS
- 19 9036-00 . SCREW, PAN HEAD NP 2
RPLD BY ITEM 19A
19A MS35207-201 . SCREW, PAN HEAD (CAD 96906 2
X 0.125 IN. LNG)
RPLS ITEM -19
(APN 33326-201)
* * *
20 6055E . VALVE ASSY, DEMAND 1
ATTACHING PARTS
- 21 AN515-4-4 . SCREW, PAN HEAD NP 1
RPLD BY ITEM 21A
21A MS35206-213 . SCREW, PAN HEAD (CAD 96906 2
X 0.250 IN. LNG)
RPLS ITEM -21
(APN 33321-213)
- 22 AN936A4 . WASHER, LOCK NP 1
RPLD BY ITEM 22A
22A MS35333-36 . WASHER, LOCK (CAD PLATED 96906 2
STEEL) (#4 DIA X 0.017 IN. THK)
(APN 33460-036)
RPLS ITEM -22
- 23 6066-00 . WASHER, FLAT NP 2
RPLD BY ITEM 23A
23A 6066-01 . WASHER, FLAT (CRES) (0.281 IN. 2
OD X 0.125 IN. ID X 0.031 IN. THK)
RPLS ITEM -23
* * *
- 24 A1120B . GASKET, DEMAND VALVE SEAT NP 1
RPLD BY ITEM 24A
(APN A-1120B)
24A 13362-00 . GASKET, DEMAND VALVE SEAT 1
RPLS ITEM -24
25 5603-00 . ADAPTER A, C 1
26 5606-00 . ADAPTER B, D 1
- 26A AD1983 .. COVER ASSY B, D 1
(APN 13410-00)
Page 10002-2
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
2
- 26B 5606-01 .. BODY, ADAPTER B, D 1
- 26C 13164-00 .. RING, RETAINING EXTERNAL B, D 1
(CARBON SPRING STEEL) (0.925
IN. ID X 0.042 IN. THK)
27 6812-00 . SCREEN, REGULATOR INLET 1
(BRASS)
- 28 5607-03 . CASE, REGULATOR NP 1
RPLD BY ITEM 28A
28A 5607-00 . CASE, REGULATOR 1
RPLS ITEM -28
- 29 6131-00 . CAP A, C 1
Page 10002-3
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
5009-00, 5009 Series Outlet Assemblies

Figure 3/GRAPHIC-35-31-55-991-195-A01
Page 10003-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
3
-1 5009-00 *** DELETED ***
- 1A 5009-2-10 OUTLET ASSY B RF
(REFER TO FIG 1A FOR NHA)
- 1B 5009-2-20 OUTLET ASSY C RF
(REFER TO FIGS 1 AND
1A FOR NHA)
- 1C 5009-2-23 OUTLET ASSY D RF
(REFER TO FIGS 1, 1A, AND
1B FOR NHA)
- 1D 5009-2-25 OUTLET ASSY E RF
1A FOR NHA)
- 1E 5009-3-20 OUTLET ASSY F RF
- 1F 5009-3-23 OUTLET ASSY G RF
- 1G 5009-4-10 OUTLET ASSY H RF
- 1H 5009-4-20 OUTLET ASSY J RF
1B FOR NHA)
- 1J 5009-4-23 OUTLET ASSY K RF
1B FOR NHA)
- 1K 5009-4-25 OUTLET ASSY L RF
1A FOR NHA)
2 59447-00 . COVER, DUST 1
3 5014-00 *** DELETED ***
4 5013-00 *** DELETED ***
5 EC9-5U *** DELETED ***
-6 5009-01 *** DELETED ***
- 6A 804376-01 . OUTLET SUBASSY NP B-L 1
(ORDER NHA)
7 10001494 .. STUD NP A 1
(ORDER NHA)
RPLD BY ITEM 7A
7A 10008915 .. STUD NP B-L 1
(ORDER NHA)
RPLS ITEM 7
8 5065-08 .. GASKET B-L 1
9 24823-00 .. VALVE B-L 1
10 5065-06 .. SPRING B-L 1
Page 10003-1
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
3
11 10001493 *** DELETED ***
12 5065-02 *** DELETED ***
13 5065-04 *** DELETED ***
14 5065-03 *** DELETED ***
15 24825-00 .. RECEPTACLE B-L 1
20 50775SERIES .. ORIFICE NP B-L 1
(APN 50775 SERIES)
(ORDER NHA)
Page 10003-2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Page 10003-3
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
5041-00, 5041 Series Outlet Assembly

Figure 4/GRAPHIC-35-31-55-991-200-A01
Page 10004-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
4
-1 5041-00 *** DELETED ***
1B FOR NHA)
(REFER TO FIG 1 AND 1A
FOR NHA)
1B FOR NHA)
- 1H 5041-4-23 OUTLET ASSY J RF
1B FOR NHA)
- 1J 5041-4-25 OUTLET ASSY K RF
- 1K 5041-5-15 OUTLET ASSY L RF
(REFER TO FIG 7 FOR NHA)
2 29558-01 *** DELETED ***
ATTACHING PARTS
3 29557-00 *** DELETED ***
* * *
Page 10004-1
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AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
4
4 5042-01 *** DELETED ***
5 5042-02 *** DELETED ***
6 5014-01 *** DELETED ***
7 5013-01 *** DELETED ***
9 5013-01 *** DELETED ***
- 10 5041-01 *** DELETED ***
- 10A 804329-01 *** DELETED ***
11 29567-00 *** DELETED ***
12 29550-00 *** DELETED ***
12A 10008934 *** DELETED ***
13 29551-00 *** DELETED ***
14 29552-00 *** DELETED ***
15 29553-01 *** DELETED ***
16 29555-00 *** DELETED ***
17 29556-00 *** DELETED ***
18 29554-00 *** DELETED ***
- 19 50775SERIES . ORIFICE, SERIES NP B-L 1
(APN 50775 SERIES)
(ORDER NHA)
- 20 804329-01 . OUTLET SUBASSEMBLY NP B-L 1
(ORDER NHA)
30 29558-01 .. COVER ASSY, DUST 1
(ORDER NHA)
ATTACHING PARTS
40 29557-00 .. NUT 1
(ORDER NHA)
* * *
50 5042-01 .. CAP 1
(ORDER NHA)
60 5042-02 .. WASHER (ALUMINUM) (1.00 IN. 1
OD X 0.641 IN. ID X 0.062 IN. THK)
(ORDER NHA)
70 29567-00 .. SETSCREW (CRES) (#8-40 THD) 1
(ORDER NHA)
80 10008934 .. BODY NP B-L 1
(ORDER NHA)
90 29551-00 .. SPRING B-L 1
(ORDER NHA)
100 29552-00 .. VALVE 1
(ORDER NHA)
110 29553-01 .. SEAT, VALVE 1
(ORDER NHA)
120 29555-00 .. SPRING 2
(ORDER NHA)
Page 10004-2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
4
130 29556-00 .. PIN 2
(ORDER NHA)
140 29554-00 .. CASE 1
(ORDER NHA)
Page 10004-3
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
5507-00, 5507 Series Outlet Assembly

Figure 5/GRAPHIC-35-31-55-991-205-A01
Page 10005-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
5
-1 5507-00 *** DELETED ***
1A FOR NHA)
1A FOR NHA)
(REFER TO FIG 1 AND 1A
FOR NHA)
1B FOR NHA)
2 5014-01 *** DELETED ***
4 5013-01 *** DELETED ***
-5 5533-00 *** DELETED ***
-6 210331 *** DELETED ***
6A 804201-01 *** DELETED ***
6B 10008596 *** DELETED ***
6C 10008595 *** DELETED ***
ATTACHING PARTS
6D 10008660 *** DELETED ***
* * *
-7 832100 *** DELETED ***
7A 10008774 *** DELETED ***
-8 832402 *** DELETED ***
8A 10008601 *** DELETED ***
-9 614010 *** DELETED ***
9A 10008602 *** DELETED ***
- 10 520058 *** DELETED ***
10A 10008603 *** DELETED ***
- 11 833012 *** DELETED ***
11A 10008594 *** DELETED ***
12 5533-01 *** DELETED ***
12A 10008947 *** DELETED ***
13 50775SERIES . ORIFICE, SERIES NP B-H 1
(ORDER NHA)
- 20 5533-00 . OUTLET SUBASSEMBLY B-H 1
(ORDER NHA)
30 804201-01 .. ADAPTER ASSY, THREADED B-H 1
40 10008596 .. SPRING, TORSION B-H 1
Page 10005-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
5
50 10008595 .. COVER, DUST B-H 1
ATTACHING PARTS
60 10008660 .. SCREW, FILLISTER HEAD (CRES B-H 1
W/ PLASTIC INSERT) (#2-56
THD X 0.250 IN. LNG)
* * *
70 10008774 .. WASHER (CAD PLATED STEEL) B-H 1
(0.985 IN. OD X 0.596 IN. ID
X 0.050 THK)
80 10008601 .. WASHER, OUTLET (COPPER B-H 1
ALLOY) (0.492 IN. OD X 0.265
IN. ID X 0.050 IN. THK)
90 10008602 .. GASKET, OUTLET B-H 1
100 10008603 .. POPPET, OUTLET B-H 1
110 10008594 .. SPRING, FLOW STOP B-H 1
120 10008947 .. BODY, OUTLET NP B-H 1
Page 10005-2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Page 10005-3
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
DELETED
Figure 6/GRAPHIC-35-31-55-991-210-A01
Page 10006-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
6
-1 5052-00 OUTLET ASSY NP A RF
(OBSOLETE)
2 5014-00 *** DELETED ***
4 5013-00 *** DELETED ***
5 5058-00 *** DELETED ***
-6 5052-02 *** DELETED ***
7 5067-01 *** DELETED ***
8 5067-02 *** DELETED ***
9 5067-04 *** DELETED ***
10 5067-07 *** DELETED ***
11 5067-06 *** DELETED ***
12 5067-05 *** DELETED ***
13 5067-03 *** DELETED ***
Page 10006-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
80116-00 thru -04, 803199-04, -05, and 807433-02 Regulator Assembly

Figure 7/GRAPHIC-35-31-55-991-215-A01
Page 10007-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
7
-1 801160-00 REGULATOR ASSY NP A RF
SUPSD BY ITEM -2
- 1A 801160-01 REGULATOR ASSY NP B RF
SUPSD BY ITEM -2
(POST SB 35-49)
1B FOR NHA)
-2 801160-03 REGULATOR ASSY C RF
SUPSDS ITEMS -1, -1A
(POST SB 35-49)
1B FOR NHA)
- 2A 801160-02 REGULATOR ASSY NP D RF
SUPSD BY ITEM -3
1B FOR NHA)
-3 801160-04 REGULATOR ASSY E RF
SUPSDS ITEM -2A
(POST SB 35-49)
1B FOR NHA)
-4 803199-04 REGULATOR ASSY F RF
-5 803199-05 REGULATOR ASSY G RF
- 5A 807433-01 REGULATOR ASSY H RF
RPLD BY ITEM -5B
(REFER TO FIG 1C FOR NHA)
- 5B 807433-02 REGULATOR ASSY H RF
RPLS ITEM -5A
(REFER TO FIG 1C FOR NHA)
-6 5520-15 . VALVE KIT, ON-OFF 1
SUPSD BY ITEM -6A
6A 5520-16 . VALVE KIT, ON-OFF 1
SUPSDS ITEM -6
(POST SB 35-49)
7 22427-01 .. PLATE, IDENTIFICATION 1
8 23274-05 .. HANDLE (GREEN) 1
ATTACHING PARTS
-9 AN345C10 .. NUT NP 1
RPLD BY ITEM -9A
- 9A MS35650-304 .. NUT (CRES) (0.190-32 THD) NP 1
RPLD BY ITEM -9B
(APN 18463-00)
- 9B 804670-03 .. NUT, FLANGE HEX 1
RPLD BY ITEM -9C
Page 10007-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
7
9C NASM21083-C3 .. NUT, SELF-LOCKING, HEXAGON 1
RPLS ITEM 9B
- 10 AN960C10L .. WASHER, LOCKING NP 1
(REPLD BY ITEM 10A)
- 10A NAS1149C0332R .. WASHER, LOCKING (CAD PLATED NP 1
STEEL) (# 10 DIA X 0.025 IN. THK)
(REPLS ITEM -10)
(REPLD BY ITEM 9B)
* * *
11 22445-01 .. WASHER, SPRING (0.706 IN. OD 1
X 0.313 IN. ID X 0.016 IN. THK)
12 5511-00 .. WASHER, FLAT (PHENOLIC) 2
(0.750 IN. OD X 0.281 IN. ID
X 0.031 IN. THK)
13 23394-01 .. NUT, PACKING 1
SUPSD BY ITEM 14A
14A 55620-01 .. PACKING, PREFORMED 1
SUPSDS ITEM -14
(POST SB 35-49)
- 15 5513-00 .. STEM ASSY, VALVE NP 1
SUPSD BY ITEM 15A
15A 10007887 .. STEM ASSY, VALVE 1
SUPSDS ITEM -15
16 5517-00 .. SEAT, PTFE 1
- 17 5518-00 .. HEAD ASSY, VALVE NP 1
(REPLD BY ITEM 17A)
17A 802883-01 .. HEAD ASSY, VALVE 1
(REPLS ITEM -17)
(POST SB 35-49)
SUPSD BY ITEM 18A
18A 55620-02 .. PACKING, PREFORMED 1
SUPSDS ITEM -18
(POST SB 35-49)
19 23393-01 .. BUSHING 1
20 5522-00 . FILTER 1
- 21 5016-00 . CAP, FILLER NP 1
(REPLD BY ITEM 21A)
21A 804202-01 . CAP, FILLER 1
(REPLS ITEMS -21, -22)
- 22 5023-00 . SEAT, FILLER CAP NP 1
(REPLD BY ITEM 21A)
23 5093-01 . VALVE ASSY, CHARGING 1
- 23A 5092-00 .. BODY NP 1
- 23B 57524-00 .. CORE, VALVE NP 1
- 23C 10002684 .. FILTER (BRONZE) NP 1
Page 10007-2
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
7
- 24 8385-00 *** DELETED ***
- 25 8384-00 *** DELETED ***
- 26 801421-00 . OUTLET ASSY, SAFETY A-E, H 1
(ALT APN 26568-01 CONTAINS
ITEMS 28, 29, 32, 33, AND 34)
- 27 801421-01 . OUTLET ASSY, SAFETY F, G 1
28 26565-00 .. CAP, SAFETY 1
29 7171-00 .. DISC, SAFETY (2700-3000 PSI) A-E, H 1
30 10003742 .. DISC, SAFETY (2500-2775 PSI) F, G 1
- 31 10006001 .. DISC, SAFETY NP 1
32 6555-00 .. GASKET (COPPER) 1
33 26567-00 .. PLUG, SAFETY 1
- 34 6370-00 . WASHER, SAFETY PLUG (FIBER) 1
RPLD BY ITEM 34A
34A 10015704 . GASKET, SEAL 1
RPLS ITEM -34
35 2661-03 . GAUGE ASSY, PRESSURE A-E 1
- 36 2661-04 . GAUGE ASSY, PRESSURE F, G 1
- 36A 801821-21 . GAUGE ASSY, PRESSURE H 1
RPLD BY ITEM 36B
36B 802821-01 . GAUGE, OXYGEN H 1
RPLS ITEM -36A
37 5043-14 . VALVE ASSY, RELIEF 1
37A 5043-14 *** DELETED ***
38 5056-00 . PLATE, IDENTIFICATION 1
ATTACHING PARTS
- 39 MS35207-202 . SCREW, PAN HD F, G 1
(APN 33326-202)
RPLD BY ITEM 39A
39A 59553-00 . SCREW (CRES W/ PLASTIC 2
INSERT) (#2-64 THD X 0.188
IN. LNG)
RPLS ITEM -39
* * *
- 40 37008-01 . SETSCREW A-E 1
(REPLD BY ITEM 40A)
40A 37008-02 . SOCKET SCREW, SET - OVAL 1
(CRES) (0.250-20 UNC-3A X
0.375 IN. LNG)
(REPLS ITEM -40)
- 41 5005-01 . CASE, SPRING A, B, D 1
SUPSD BY ITEM 41A
Page 10007-3
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
7
41A 5005-03 . CASE, SPRING C, E, F, 1
SUPSDS ITEM -41 G, H
(POST SB 35-49)
- 42 8561-00 . GUIDE, SPRING NP A-E 1
(REPLD BY ITEM 42A)
42A 8561-02 . GUIDE, SPRING 1
(REPLS ITEM -42)
43 5003-00 . SPRING, ADJUSTING 1
44 5034-00 . PLATE, DIAPHRAGM 1
- 45 5033-00 . RING, SLIP 3
SUPSD BY ITEM 45A
45A 5033-02 . RING, SLIP 1
SUPSDS ITEM -45
45B 5033-00 . RING, SLIP H 1
46 5032-01 . DIAPHRAGM 1
47 5031-00 . PLATE, THRUST 1
48 5030-01 . HOLDER, SEAT 1
- 49 5029-00 . SEAT A, B, D 1
SUPSD BY ITEM 49A
49A 803129-01 . SEAT A, B, D 1
SUPSDS ITEM -49
(POST SB 35-49)
50 5028-00 . PIN, THRUST 1
51 5002-00 . GUIDE, THRUST PIN 1
52 5027-00 . SPRING 1
- 53 5018-00 . TUBE, DRAIN A, B, D 1
SUPSD BY ITEM 53A
- 53A 10003305 . TUBE, DRAIN A, B, D 1
SUPSDS ITEM 53
(POST SB 35-49)
- 54 59776-01 . SEAL, METAL BOSS F, G 1
- 54A 10013868 . PACKING, PREFORMED H 1
RPLD BY ITEM -54B
54B 58532-00 . PACKING, PREFORMED H 1
RPLS ITEM 54A
- 55 5053-07 . BODY (ALUMINUM - 2 OUTLET NP A 1
PORTS)
SUPSD BY ITEM 58
- 56 10003209 . BODY (ALUMINUM - 2 OUTLET NP B 1
PORTS)
SUPSD BY ITEM 58
- 57 10003319 . BODY (ALUMINUM - 3 OUTLET NP D 1
PORTS)
SUPSD BY ITEM 59
Page 10007-4
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
7
- 58 27170-01 . BODY (BRASS - 2 OUTLET PORTS) NP A, B, C 1
SUPSDS ITEMS -55, -56
(POST SB 35-49)
RPLD BY ITEM 58A
58A 807803-01 . BODY AND TUBE ASSEMBLY A, B, C 1
RPLS ITEM -58
- 59 27170-02 . BODY (BRASS - 3 OUTLET PORTS) NP D, E 1
SUPSDS ITEM -57
(POST SB 35-49)
RPLD BY ITEM 59A
59A 807803-02 . BODY AND TUBE ASSEMBLY D, E 1
RPLS ITEMS 53A, 59
- 60 27170-05 . BODY (BRASS - 2 OUTLET PORTS) NP F, H 1
RPLD BY ITEM 60A
60A 807803-05 . BODY AND TUBE ASSEMBLY F, H 1
RPLS ITEM -60
- 61 27170-06 . BODY (BRASS - 3 OUTLET PORTS) NP G 1
RPLD BY ITEM 61A
61A 807803-06 . BODY AND TUBE ASSEMBLY G 1
RPLS ITEM -60
- 62 5057-14 . PLATE, IDENTIFICATION F, G, H 1
63 10002408 . PLATE, IDENTIFICATION A-E 1
64 MS21318-7 . SCREW, DRIVE (CRES) (#0 2
X 0.125 IN. LNG)
(APN 18341-00)
(ALT APN 33343-007)
70 5041-5-15 . OUTLET ASSY H 1
75 5041-5-15 . OUTLET ASSY H 1
Page 10007-5
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
802856-01 Outlet Assembly

Figure 8/GRAPHIC-35-31-55-991-220-A01
Page 10008-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
8
-1 802856-01 OUTLET ASSY RF
1B FOR NHA)
2 10008644 . RETAINER, DUST COVER 1
3 10005614 . FITTING, DISCONNECT 1
4 36874-01 . PIN, GROOVE 2
5 10005617 . COVER, DUST 1
6 27511-01 . LABEL, WARNING 1
-7 36862-02 . PACKING, PREFORMED 1
RPLD BY ITEM 7A
7A 10009328 . GASKET 1
RPLS ITEM -7
8 36588-04 . SPRING, POPPET 1
9 10005616 . POPPET, DISCONNECT 1
10 36636-01 . RING, QUAD 1
11 10005615 . BODY, DISCONNECT 1
12 2800C14A . PACKING, PREFORMED 1
(ALT APN 18012-00)
13 2800C10A . PACKING, PREFORMED 1
(ALT APN 55622-00)
Page 10008-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
2661-03, 2661-04, 802821-01Pressure Gauge Assembly

Figure 9/GRAPHIC-35-31-55-991-225-A01
Page 10009-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
9
1 2661-03 GAUGE ASSEMBLY, PRESSURE NP A RF
(30 THREADS PER INCH,
MACHINED)
RPLD BY ITEM 1A
1A 2661-03 GAUGE ASSEMBLY, PRESSURE NP B RF
ROLLED)
RPLS ITEM 1
RPLD BY ITEM 1B
1B 2661-03 GAUGE ASSEMBLY, PRESSURE NP C RF
(4 LUGS AT 90 DEGREES)
RPLS ITEM 1A
RPLD BY ITEM 1C
1C 2661-03 GAUGE ASSEMBLY, PRESSURE NP D RF
(3 LUGS AT 120 DEGREES)
RPLS ITEM 1B
RPLD BY ITEM 1D
1D 2661-03 GAUGE ASSEMBLY, PRESSURE E RF
ROLLED)
RPLS ITEM 1C
1E 2661-04 GAUGE ASSEMBLY, PRESSURE F RF
ROLLED)
- 1F 802821-21 GAUGE ASSEMBLY G RF
RPLD BY ITEM -1G
- 1G 802821-01 GAUGE ASSEMBLY G RF
RPLS ITEM -1F
5 56750-00 BEZEL (METAL, BLACK) NP A 1
5A 21217-11 BEZEL (METAL, BLACK) E, F 1
-7 804620-01 BEZEL, GAUGE G 1
10 13753-00 LENS (PLASTIC) A 1
10A 21217-12 LENS (PLASTIC) E, F 1
15 56750-01 LENS WITH BEZEL (ALL PLASTIC) D 1
15A 56750-02 LENS WITH BEZEL (ALL PLASTIC) B, C 1
20 21217-13 GASKET E, F 1
25 21217-14 LABEL, RELIEF NP E, F 1
Page 10009-1
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
Portable Cylinder Assembly 803668-01 Optional Next Higher Assembly

Figure 10/GRAPHIC-35-31-55-991-230-A01
Page 10010-0
35-31-55 Jun 21/16
AVOX SYSTEMS INC.
803668-01, 807434-01, 9700 SERIES, 9800 SERIES
UNITS
PART No. CODE
1234567
ASSY
10
1 803668-01 CYLINDER ASSY, PORTABLE RF
(DEHAVILLAND SPEC NO.
8SCO403)
-2 9700B1XBBF25A . CYLINDER ASSY, PORTABLE 1
(SPN 9700-B1X-BBF25A)
-3 803177-01 . HARNESS ASSY WITH MASK 1
AND STORAGE BAG
4 801809-01 .. BAG ASSY, MASK STORAGE 1
-5 36879-01 .. FASTENER, VELSTRAP W/ 1
HOOK AND LOOP
-6 289-601-211-2 .. MASK ASSY, PAX 2
RPLD BY ITEM 6A
6A 289-601-211 .. MASK ASSY, PAX 2
RPLS ITEM -6
SEE CMM 35-22-26 FOR BKDN)
-7 5065-10 .. CONNECTOR, PLUG-IN 2
[FULL-FLOW (NON-METERED)
TYPE] (SIMILAR TO AN6009 TYPE)
8 801660-00 .. STRAP, SLING 1
ATTACHING PARTS
9 13160-00 . CLAMP 1
* * *
10 10007729 . TAG, OXYGEN 1
- 11 10007721 . LABEL, GAUGE 1
12 800409-00 . CAP ASSY, FILLER 1
13 10007738 . DECAL, OUTLET ID - NORMAL 2
14 10007739 . DECAL, OUTLET ID - FIRST AID 1
- 50 28022-00 . OVERHAUL KIT FOR THE 1
9700 SERIES PCA
(REFER TO FIG 1, ITEM
NUMBERS -750 THRU -810
FOR FOR BKDWN)
Page 10010-1
35-31-55 Jun 21/16

CMM - 35-31-55 Rev 8

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ZODIAC AEROSPACE SERVICES

TECHNICAL PUBLICATION DEPARTMENT

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LOCATIONS DESIGNATION DESCRIPTION OF CHANGE

LOCATIONS DESIGNATION DESCRIPTION OF CHANGE

INSPECTION/CHECK N Revised paragraph 4.D and Table 5004 to

LOCATIONS DESIGNATION DESCRIPTION OF CHANGE

ILLUSTRATED PARTS LIST Updated section to new format.

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(ZODIAC OXYGEN SYSTEMS US)

COMPONENT MAINTENANCE MANUAL

9700-C1A-BF20B 9700-C1B-BF23D 9700-G2A-BF20D 9800-1C1A-E20B 9800-2C1A-X0M

9700-C1A-BF23AM 9700-C3C-BF20D 9700-G2A-BF23D 9800-1C1A-F20B 9800-2D1A-BF23A

9700-C1A-BF23AN 9700-D1A-BBF20B 9700-G2A-BF25A 9800-1C1A-F23A 9800-2D1A-E23AM

9700-C1A-BF23B 9700-D1A-BBF23A 9700-G2A-FF25B 9800-1C1A-X0N 9800-2D1A-F20BM

9700-C1A-BF23D 9700-F1A-BF23AM 9700-G2A-F10AN 9800-1C1A-X0X 9800-2D1A-F23AM

REVISION No.:8 TP Page 1

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RECORD OF TEMPORARY REVISIONS

TEMP INSERTED REMOVED

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SERVICE BULLETIN LIST

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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

LIST OF EFFECTIVE PAGES (Cont'd)

SUBJECT PAGE DATE SUBJECT PAGE DATE

1015 Jun 21/16 4003 Jun 21/16

LIST OF EFFECTIVE PAGES (Cont'd)

SUBJECT PAGE DATE SUBJECT PAGE DATE

6009 Jun 21/16 7034 Jun 21/16

7015 Jun 21/16 FIXTURES, EQUIPMENT 9002 Jun 21/16

7016 Jun 21/16 AND CONSUMABLES 9003 Jun 21/16

7017 Jun 21/16 9004 Jun 21/16

7018 Jun 21/16 9005 Jun 21/16

7019 Jun 21/16 9006 Jun 21/16

7020 Jun 21/16 SPECIAL PROCEDURES 11001 Jun 21/16

LIST OF EFFECTIVE PAGES (Cont'd)

SUBJECT PAGE DATE SUBJECT PAGE DATE

LIST OF EFFECTIVE PAGES (Cont'd)

SUBJECT PAGE DATE SUBJECT PAGE DATE

10007-4 Jun 21/16

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DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TESTING AND FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

TABLE OF CONTENTS (Cont'd)

SCHEMATICS AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOT APPLICABLE

TABLE OF CONTENTS (Cont'd)

TABLE OF CONTENTS (Cont'd)

TABLE OF CONTENTS (Cont'd)

TABLE OF CONTENTS (Cont'd)

FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES . . . . . . . . . . . . . . . . . . . . . 9001

SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11001

TABLE OF CONTENTS (Cont'd)

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOT APPLICABLE

SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOT APPLICABLE

REWORK .............................................................................. 16001

ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IPL 10001 1

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DESCRIPTION AND OPERATION

TESTING AND FAULT ISOLATION