Narrative:

October 2009. The avionics shop has been gathering information for the testing and repair of the crj-700 passenger service units (psu). During the time the avionics shop has been gathering information; four of the psu's have been sent to the shop. The psu's have been stored in boxes on the in-coming unserviceable shelves. Today the shop received the drawings needed to build the psu test panel. Mr. X and I were reviewing the drawings and formulating plans for construction of the psu test panel. I pointed out to mr.X that there is an electrical activated solenoid to open the oxygen mask deploy door. From my past experience I knew the door has a catch to keep the door from fully opening; when the solenoid is tested.I was showing mr X the operation of the catch when I noticed that the oxygen generator safety pin was not installed. I checked the three other psu's and found another psu without the pin installed. In both cases the safety pin and warning flag were in the box. While preparing this report; I reviewed the crj amm procedures for removal of the psu and oxygen generator; I found the amm procedure for removal of the psu does not include installing the safety pin for the oxygen generator. The instruction for installing the safety pin is in the oxygen generator removal task; component maintenance manual(cmm) 25-28-48 for passenger service units 932610X with warnings stating; ' warning: when working with the oxygen module; do not pull on the lanyards; this will pull the release pin and fire the generator. The generator surface temperature may reach 550 degrees F. It will take 60 minutes to cool for safe handling and replacement. Warning: do not pull on the lanyard when you do maintenance in the mask container. The oxygen generator is a pyrotechnic activated device. If the release pin; connected to the lanyard is removed; the generator will operate. The oxygen generator can have surface temperature higher than 550 degrees F (288 degrees C) and can cause burns.' reference: crj amm 35-20-00; task 35-20-00-710 for oxygen system; test latch or cmm 25-28-48 test and fault isolation 5. Operational test of the passenger oxygen door latch reference: crj amm 35-21-03; task 35-21-03-00-801 for removal of oxygen generator. Safety pin installation reference: crj amm TR 25-03-54; task 25-28-01- removal of psu. Safety pin and red flag not installed. A lack of training may be a cause; but most likely no instruction in removal task. Update amm psu removal task to include the installation of the safety pin. Have the stock room reject crj psu with O2 generators that don't have the safety pins installed.

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Original NASA ASRS Text

Title: An Avionics Shop Technician reports finding the CRJ-700 AMM procedures for Removal and Installation of PSUs do not include installing the safety pin in the oxygen generator. Incoming unserviceable PSUs have been found stored in boxes without the Safety pins installed.

Narrative: October 2009. The Avionics Shop has been gathering information for the testing and repair of the CRJ-700 Passenger Service Units (PSU). During the time the Avionics Shop has been gathering information; four of the PSU's have been sent to the Shop. The PSU's have been stored in boxes on the in-coming Unserviceable shelves. Today the Shop received the drawings needed to build the PSU Test panel. Mr. X and I were reviewing the drawings and formulating plans for construction of the PSU Test Panel. I pointed out to Mr.X that there is an electrical activated solenoid to open the Oxygen mask deploy door. From my past experience I knew the door has a catch to keep the door from fully opening; when the solenoid is tested.I was showing Mr X the operation of the catch when I noticed that the Oxygen Generator Safety pin was not installed. I checked the three other PSU's and found another PSU without the pin installed. In both cases the Safety pin and Warning flag were in the box. While preparing this report; I reviewed the CRJ AMM procedures for removal of the PSU and Oxygen Generator; I found the AMM procedure for removal of the PSU does not include installing the Safety Pin for the Oxygen Generator. The instruction for installing the Safety Pin is in the Oxygen Generator removal Task; Component Maintenance Manual(CMM) 25-28-48 for Passenger Service Units 932610X with Warnings stating; ' WARNING: WHEN WORKING WITH THE OXYGEN MODULE; DO NOT PULL ON THE LANYARDS; THIS WILL PULL THE RELEASE PIN AND FIRE THE GENERATOR. THE GENERATOR SURFACE TEMPERATURE MAY REACH 550 DEGREES F. IT WILL TAKE 60 MINUTES TO COOL FOR SAFE HANDLING AND REPLACEMENT. WARNING: DO NOT PULL ON THE LANYARD WHEN YOU DO MAINTENANCE IN THE MASK CONTAINER. THE OXYGEN GENERATOR IS A PYROTECHNIC ACTIVATED DEVICE. IF THE RELEASE PIN; CONNECTED TO THE LANYARD IS REMOVED; THE GENERATOR WILL OPERATE. THE OXYGEN GENERATOR CAN HAVE SURFACE TEMPERATURE HIGHER THAN 550 DEGREES F (288 DEGREES C) AND CAN CAUSE BURNS.' Reference: CRJ AMM 35-20-00; Task 35-20-00-710 for Oxygen System; Test Latch or CMM 25-28-48 Test and Fault Isolation 5. Operational Test of the Passenger Oxygen Door Latch Reference: CRJ AMM 35-21-03; Task 35-21-03-00-801 for removal of Oxygen Generator. Safety Pin installation Reference: CRJ AMM TR 25-03-54; Task 25-28-01- Removal of PSU. Safety pin and Red flag not installed. A lack of training may be a cause; but most likely no Instruction in Removal Task. Update AMM PSU Removal Task to include the installation of the safety pin. Have the Stock room reject CRJ PSU with O2 Generators that don't have the Safety pins installed.

Data retrieved from NASA's ASRS site as of April 2012 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.