TECHNICAL BULLETIN INSTALLATION AND FITTING INSTRUCTIONS FOR M45 MASK THERMOPLASTIC LINER DISTRIBUTION STATEMENT C : Distribution authorized to U.S. Government agencies and their contractors to protect technical or operational information. This determination was made on 1 September 1994. Other requests for this document will be referred to: Commander, USA SBCCOM, ATTN: AMSSB-RBD-B, 5183 Blackhawk Road, Aberdeen Proving Ground, MD 21010-5424. DESTRUCTION NOTICE : Destroy by any method that will prevent disclosure of contents or reconstruction of the document. HEADQUARTERS, DEPARTMENT OF THE ARMY 30 JULY 1999
WARNING SUMMARY This warning summary includes general safety precautions and instructions that must be understood and applied during the operation and maintenance of this system/equipment to ensure personnel against injury, death, or long-term health hazards. A summary of safety and hazardous material warnings that should be heeded in conduct of operation and maintenance is provided below. WARNING Proper fitting of the helmet with the M45 thermoplastic liner is essential to the functioning of the HGU- 56/P when used with the M45 Mask, all of its modules, and the safety of the operator. Take as much time as necessary to install and fit the kit properly. Use extreme care in checking fit. Handle the heated thermoplastic liner carefully; the plastic layers will be hot. Touch the fabric cover only. Wear gloves if necessary. a
LIST OF EFFECTIVE PAGES/WORK PACKAGES Original.. 0.. 30 Jul 99 TB 3-4240-341-20 Date of issue for the original manuals is: TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 5 AND TOTAL NUMBER OF WORK PACKAGES IS 5, CONSISTING OF THE FOLLOWING: Page/WP *Change Page/WP *Change No. No. No. No. Title 0 Warnings 0 A 0 B Blank 0 i - ii 0 WP 0001 00 (2 pgs) 0 WP 0002 00 (3 pgs) 0 WP 0003 00 (4 pgs) 0 WP 0004 00 (3 pgs) 0 WP 0005 00 (1 pgs) 0 *Zero in this column indicates an original page. A
TECHNICAL BULLETIN INSTALLATION AND FITTING INSTRUCTIONS FOR M45 MASK THERMOPLASTIC LINER REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual direct to: Commander, USA SBCCOM, ATTN: AMSSB-RBD-B, 5183 Blackhawk Road, Aberdeen Proving Ground, MD 21010-5424. A reply will be furnished to you. DISTRIBUTION STATEMENT C : Distribution authorized to U.S. Government agencies and their contractors to protect technical or operational information. This determination was made on 1 September 1994. Other requests for this document will be referred to: Commander, USA SBCCOM, ATTN: AMSSB-RBD-B, 5183 Blackhawk Road, Aberdeen Proving Ground, MD 21010-5424. i
TABLE OF CONTENTS WP Sequence No. WARNING SUMMARY General Information... 0001 00 Initial Sizing and Fitting... 0002 00 Custom Sizing and Fitting... 0003 00 Maintenance Procedures... 0004 00 M45 Thermoplastic Liner Parts List... 0005 00 ii
GENERAL INFORMATION 0001 00 M45 Mask Thermoplastic Liner 0001 00-1
GENERAL INFORMATION 0001 00 DESCRIPTION The Thermoplastic Liner (TPL) used with the M45 Mask consists of a Layer Assembly (1), Cover Assembly (2) and Brow Pad (3). It is cut smaller than the standard thermoplastic liner to allow room for the M45 mask and hood. When the M45 mask is not worn, a brow pad included with the TPL fills the space normally taken up by the mask. 1 2 3 OPERATION Use the M45 thermoplastic liner only when you plan to wear the M45 mask. The brow pad is used in two situations: while you are on a mission and have removed the M45 mask, and when you are going on a mission without the M45 mask donned but you expect to don the mask during the mission. When you use the M45 TPL, the helmet bag that you carry to the aircraft should contain either the M45 mask or the brow pad; you should be wearing whichever item is not in the helmet bag. If you do not plan to use the M45 mask, do not use the M45 thermoplastic liner or the brow pad; use the standard thermoplastic liner instead. 0001 00-2
INITIAL SIZING AND FITTING 0002 00 INITIAL SETUP Maintenance Level Unit Materials/Parts Helmet, Flyer's, HGU-56/P (Items 2-7, WP 0005) Mask, Chemical-Biological: M45 (Items 8-11, WP 0005) Thermoplastic Liner, M45 (Items 17-22, WP 0005) Personnel Required Operator wearing a properly sized and fitted M45 Mask and HGU-56/P Helmet Assembly with standard TPL ALSE Specialist/Technician with ASI of H2/Q2 (ALSE Qualified) PREPARING THE HELMET WARNING Proper fitting of the helmet with the M45 thermoplastic liner is essential to the functioning of the HGU-56/P when used with the M45 Mask, all of its modules, and the safety of the operator. Take as much time as necessary to install and fit the kit properly. Use extreme care in checking fit. NOTE If optical systems, Aviator's Night Vision Imaging System (ANVIS) or AH-1 are to be used, check helmet fit with optical systems attached. During the fitting, the operator must wear a properly sized, fitted, and adjusted M45 Mask. Have the operator don the mask before donning the helmet. In preparation for the fitting procedure, operator's with long hair should arrange their hair so that it lies flat and is completely covered by the helmet. Elevated hair styles such as buns or French braids will prevent proper fitting of the helmet. The helmet must be worn the same way thereafter. 0002 00-1
INITIAL SIZING AND FITTING 0002 00 PREPARING THE HELMET - Continued 1. Remove the standard thermoplastic liner from the helmet. 2. Attach the flat side of the brow pad (1) to the hook fasteners at the front of the energy-absorbing liner (2), ensuring that the bottom edge of the brow pad (3) is flush with the front edge of the energyabsorbing liner. 3. Install the M45 thermoplastic liner in the helmet, ensuring that: the front edge of the thermoplastic liner is flush with the top edge of the brow pad, the thermoplastic liner is against the crown of the helmet, the holes (4) in the front of the thermoplastic liner align with the plenum ports (5) the rear edge of thermoplastic liner is aligned with the top edge of the nape strap pad and sits squarely in the helmet, and the nape strap pad (6) is completely pulled down so that the keeper tab is taut. 1 3 3 2 5 4 6 4. Remove the brow pad from the helmet. 0002 00-2
INITIAL SIZING AND FITTING 0002 00 INITIAL FITTING OF THE HELMET 1. With the Mask donned, have the operator don the helmet as follows: a. Hook the thumbs in the earcups and spread the helmet slightly. b. Position the helmet firmly against the forehead; rotate the helmet rearward and down onto the head. c. Press the helmet down firmly with both hands to ensure that the helmet is properly positioned on the head. 2. Align the helmet with the forehead reference point. 3. Adjust the earcups so that they cover the operator s ears. Check earseal compression and adjust as necessary in accordance with TM 1-8415-216-12&P, paragraph 4-11. 4. Fasten and adjust the chinstrap. 5. Lower the visors to check centering and nose clearance. If necessary, adjust the visors as follows: a. Loosen the downstop locking screws (one on each side of the visor) and adjust as necessary. b. When the desired visor position is attained, tighten the screws. 6. Adjust the nape strap pad for the closest fit possible. 7. Check the fit of the pad with your index finger. 1 8. Ask the operator to evaluate the fit. If the fit is 2 acceptable, skip to Step 12. If a pressure point exists, proceed to Step 9. 9. Have the operator remove the helmet. Add headband fitting pads (1) to the energy-absorbing liner (2) where it contacts the brow pad, two on either side of the pressure point to even the pressure. 10. Have the operator don the helmet again. If a pressure point remains, custom-fitting may be required. Refer to the WP 0003 00. NOTE If the operator cannot be fitted in accordance with the fitting instructions, contact the United States Army Aeromedical Research Laboratory (USAARL). 11. Repeat Steps 4-7 for a final fit check with the mask. NOTE Adjust ANVIS goggles as necessary for maximized field of view. 12. If optical systems (ANVIS goggles, AH-1 sight) are used, place the systems in normal operating position and check for full operational capability in accordance with TM 11-5855-263-10 for ANVIS goggles and TM 9-1270-212-14&P for the AH-1 sight. 13. Remove the helmet and the mask. 14. Reinstall the brow pad. Ensure the bottom edge of the brow pad is flush with the edge of the energy absorbing liner. 15. Have the operator don the helmet without the mask. Repeat steps 4-9. 16. After the first flight, recheck and adjust as necessary the helmet straps, the thermoplastic liner, and the earcups. 0002 00-3
CUSTOM SIZING AND FITTING 0003 00 INITIAL SETUP Maintenance Level Unit Materials/Parts Gloves (Item 1, WP 0005) Helmet, Flyer's, HGU-56/P (Items 2-6, WP 0005) Mask, Chemical-Biological: M45 (Items 8-11, WP 0005) Oven (Item 12, WP 0005) Oven Thermometer (Local purchase) Talcum Powder (Item 14, WP 0005) Tape, Pressure-Sensitive Adhesive (Item 15, WP 0005) Thermoplastic Liner, M45 (Items 17-22, WP 0005) Timer or equivalent (Local purchase) Personnel Required Operator wearing a properly sized and fitted M45 Mask ALSE Specialist/Technician with ASI of H2/Q2 (ALSE Qualified) WARNING Proper fitting of the helmet with the M45 thermoplastic liner kit is essential to the functioning of the HGU-56/P when used with the M45 CB Protective Mask, all of its modules, and the safety of the operator. Take as much time as necessary to install and fit the kit properly. Use extreme care in checking fit. CAUTION If you are using a non-convection oven to heat the thermoplastic liner, ensure that the upper burner elements do not activate during heating, or plastic layers will melt. 0003 00-1
CUSTOM SIZING AND FITTING 0003 00 PREPARING THE THERMOPLASTIC LINER NOTE Do not use a microwave oven; it will not heat the plastic layers. 1. Set the oven rack (1) to the lowest position (2); heat the oven to 200 F ± 5 F (93.3 C ± 2.8 C). 2 1 CAUTION Before you place the thermoplastic liner in the oven, ensure that the cover is attached properly. If the cover is installed backward or not aligned properly, the layers could become damaged during fitting, making the TPL unserviceable. 2. Place the thermoplastic liner in the center of the rack in the heated oven, cloth side on rack. 3. Ensure that the oven stabilizes at the temperature specified in Step 1 before you set the timer. 4. Set the timer, stopwatch, or equivalent for 10 minutes. Heat the thermoplastic liner for approximately 10 minutes. 5. While the thermoplastic liner heats, review HELMET CUSTOM FITTING, steps 1-5, so that they may be completed in 30 seconds or less. 6. Check the oven temperature with an over thermometer every three to five minutes during the heating process. Adjust the oven controls if the temperature falls outside the range specified in Step 1. 7. Describe the fitting procedure to the operator being fitted. PREPARING THE HELMET AND MASK If headband fitting pads are installed in the helmet, remove them. Attach the brow pad to the hook fasteners on the energy-absorbing liner, ensuring that the bottom edge of the brow pad is flush with the front edge of the liner. Cover the hook fastener on the nape strap pad with pressure-sensitive tape to ease installation of the heated thermoplastic liner. Loosen the nape strap pad. Sprinkle a light coat of talcum powder over the mask hood to ease donning of the hot TPL. 0003 00-2
CUSTOM SIZING AND FITTING 0003 00 HELMET CUSTOM FITTING WARNING Handle the heated thermoplastic liner carefully; the plastic layers will be hot. Touch the fabric cover only. Wear gloves if necessary. 1. Remove the thermoplastic liner from the oven. NOTE Steps 1-5 should be completed in 30 seconds or less. CAUTION Do not deform the hot, soft thermoplastic liner by pressing too hard in any one area when positioning the liner in the helmet. 2. Squeezing the sides of the thermoplastic liner (1) to clear the earcups (2), install the liner in the helmet. Ensure that the label and holes on the liner are positioned toward the front of the helmet. 3. Have the operator hold the helmet upside down. Position the thermoplastic liner so that the front edge is flush with the top edge of the brow pad. Ensure that the liner is centered in the helmet. 4. Position the top of the thermoplastic liner in the helmet. Position the rear of the thermoplastic liner against the top edge of, but not down on, the nape strap pad while holding the nape strap pad keeper tab taut. 5. Remove the brow pad. 1 2 CAUTION When donning or removing the helmet, spread the helmet just enough to clear the head. Excessive spreading may damage the helmet. 6. Have the operator hook his/her thumbs in the earcups and spread the helmet slightly. Place the front of the helmet against the forehead reference point. Hold the edge of the thermoplastic liner and nape strap pad with your hand and pull down. Have the operator don the helmet and rotate the helmet rearward. 0003 00-3
CUSTOM SIZING AND FITTING 0003 00 HELMET CUSTOM FITTING - Continued 7. Have the operator pull downward with his/her hands on top of the helmet until it is seated firmly on the head. Lower the visor to check nose centering and clearance. Fasten the chinstrap and the nape strap and tighten them as much as possible without causing excessive discomfort. This will optimize the operator s peripheral vision. Have the operator maintain as much downward pressure as possible, without causing excessive discomfort, for 3-5 minutes. NOTE The thermoplastic liner should be compressed as much as possible; this will afford a low center of gravity and long-lasting comfort. 8. Release pressure on top of the head and remove the helmet. Ensure that the thermoplastic liner lies smoothly in the helmet. NOTE If the thermoplastic liner is not properly fitted, reheat the thermoplastic liner and repeat the fitting procedure. 9. Remove the pressure sensitive tape from the nape strap (1) pad hook fastener. 10. Have the operator don the helmet. Adjust the earcups; tighten the nape strap and the chinstrap. 11. Perform a final fit check. No pressure points 1 should exist; if they do, remove the thermoplastic liner from the fitting shell and repeat the fitting procedure. 12. If the operator does not have a full field of view with the ANVIS, remove the thermoplastic liner from the helmet and reheat it. Reinstall the thermoplastic liner in the helmet, have the operator don the helmet, and press the front of the helmet against the head to compress the thermoplastic liner as much as possible. 13. If the fit is still too tight after the thermoplastic liner has been custom-fitted, select the next larger helmet size. 14. If the helmet fits properly, perform Steps 2-6 of HELMET CUSTOM FITTING for a final fit check. 0003 00-4
MAINTENANCE PROCEDURES 0004 00 CLEANING COMPONENT CONDITION PROCEDURE Brow Pad Dirt, Stains, Grease Hand wash, cool or lukewarm water, mild liquid detergent, air dry only Cover Assembly Dirt, Stains, Grease Hand or machine (gentle cycle) wash, cool or lukewarm water, mild detergent, air dry Layer Assembly Dirt Wipe clean with damp cloth. Replace 2-sided tape 0004 00-1
MAINTENANCE PROCEDURES 0004 00 REPLACING BROW PAD INITIAL SETUP Maintenance Level Unit Materials/Parts Brow Pad Personnel ALSE Specialist/Technician with ASI of H2/Q2 (ALSE Qualified) 1. Remove the brow pad (1) from the helmet (2). 2. Attach the flat side of the replacement brow pad to the hook fasteners at the front of the energyabsorbing liner (3), ensuring that the bottom edge of the brow pad (4) is flush with the front edge of the energy-absorbing liner. 1 4 4 3 2 0004 00-2
MAINTENANCE PROCEDURES 0004 00 REPLACING COVER ASSEMBLY INITIAL SETUP Maintenance Level Unit Materials/Parts Personnel Cover Assembly Tape PSA Double Sided (Item 16, WP 0005) Shears, Bent Trimmers (Item 13, WP 0005) ALSE Specialist/Technician with ASI of H2/Q2 (ALSE Qualified) 1. Squeeze the sides of the thermoplastic liner to clear the earcups, and remove the TPL from the helmet (See WP 0003, HELMET CUSTOM FITTING, Step 2). 2. Remove the thermoplastic liner cloth cover (1) as follows: 3. Remove and discard the thread (2) attaching the cover to the plastic layers (3). Replacement of the thread is not necessary. 4. Fold the sides of the cover down to expose the double-sided tape (4). 5. Remove the cover from the layers. 6. Remove the double-sided tape from the layer assembly. 7. Cut two 2-1/2-inch pieces of doublesided tape. 8. Attach a piece of double-sided tape to each side of the layer assembly (where the old tape was removed). 9. Turn the replacement cloth cover inside out. Place the cover inside the layer assembly. Fold the sides of the cloth cover over the layer assembly. Ensure that the cover is positioned properly. 3 10. Reinstall the TPL in the helmet (See WP 0003, HELMET CUSTOM FITTING, Step 2). Align the rear edge of the liner with the top edge of the nape strap pad; align the front edge of the liner with the top edge of the brow pad. Ensure that the nape hanger strap is taut and that the hook-and-pile fasteners are engaged. 4 2 1 0004 00-3
M45 THERMOPLASTIC LINER PARTS LIST 0005 00 ITEM NOMENCLATURE PART NUMBER NATIONAL STOCK NUMBER 1 Gloves, Men s J729 8415-01-189-6387 2 3 4 5 6 7 8 9 10 11 12 Helmet, Flyer s, HGU-56/P (Extra Large) Helmet, Flyer s, HGU-56/P (Large) Helmet, Flyer s, HGU-56/P (Medium) Helmet, Flyer s, HGU-56/P (Small) Helmet, Flyer s, HGU-56/P (Extra Small) Helmet, Flyer s, HGU-56/P (Extra-Extra Small) Mask, Chemical-Biological; M45 (Extra Small) Mask, Chemical-Biological; M45 (Small) Mask, Chemical-Biological; M45 (Medium) Mask, Chemical-Biological; M45 (Large) Oven, Baking and Roasting, Portable 1680-ALSE-101-1 8415-01-394-8032 1680-ALSE-101-2 8415-01-394-8033 1680-ALSE-101-3 8415-01-394-8036 1680-ALSE-101-4 8415-01-394-8034 1680-ALSE-101-5 8415-01-394-8035 1680-ALSE-101-6 8415-01-394-6474 5-1-2800-10 4240-01-414-4034 5-1-2800-20 4240-01-414-4035 5-1-2800-30 4240-01-414-4051 5-1-2800-40 4240-01-414-4052 T4800 7310-01-364-4043 13 Shears, Bent Trimmers GGG-S-00278 5110-00-162-2203 14 Talcum Powder U-T-30 8510-00-817-0295 15 Tape, Pressure Sensitive Adhesive UU-T-93 7510-00-198-5831 16 Tape PSA Double Sided 750-01-317-8459 17 18 19 20 21 22 Thermoplastic Liner, M45 (Extra-Extra Small) Thermoplastic Liner, M45 (Extra Small) Thermoplastic Liner, M45 (Small) Thermoplastic Liner, M45 (Medium) Thermoplastic Liner, M45 (Large) Thermoplastic Liner, M45 (Extra Large) 5-1-2873-10 4240-01-455-7982 5-1-2873-20 4240-01-456-4510 5-1-2873-30 4240-01-456-4509 5-1-2873-40 4240-01-456-4512 5-1-2873-50 4240-01-456-4511 5-1-2873-60 4240-01-456-4516 0005 00-1
By Order of the Secretary of the Army: Official: ERIC K. SHINSEKI General, United States Army Chief of Staff JOEL B. HUDSON Administrative Assistant to the Secretary of the Army 9921101
PIN: 077437-000