INSTALLATION INSTRUCTIONS HELMET PAD KIT 2005 GENTEX Corporation
INSTALLATION INSTRUCTIONS HELMET PAD KIT PART NUMBERS 00B11094-7 AND 00B11094-8 DESCRIPTION The helmet pad kit (Figure 1) permits the attachment of the adjustable pad suspension in the Tactical Ballistic Helmet (TBH) and the Police Ballistic helmet. The kit consists of hook fastener tapes of various lengths, adjustable pads, and two screws. The adjustable pad suspension system consists of a set of eight sizing pads attached to the attachment tapes inside the helmet shell. Three pads are attached at the front, three at the rear, and two in the crown area. (Exception: Kit 00B11094-8 also has two extra pads to be installed at the sides.) The crown pads can be spaced farther apart to permit the use of an over-the-head headset. Each sizing pad consists of three impact-absorbing foam filler pads (two ¼ thick and one ½ thick) inside a cover. The ¼ foam pads can be removed or added to allow sizing adjustments for optimum stability and comfort. This booklet provides instructions for installing the kit. PADS SCREWS HOOK FASTENER TAPES COVER PAD DETAIL FOAM PADS Figure 1. Helmet Pad Kit 1
PROCEDURE Tools/Materials/Equipment Needed Flat-tip screwdriver Ruler or measuring tape Pencil Installing Hook Fastener Tapes 1. Remove the suspension and retention assemblies from the helmet. Set aside the screws, A-nuts, and retention assembly for reinstallation later. 2. Referring to Figure 2, install one 8-32 x 3/8 screw (supplied with the kit) and one of the existing A-nuts into the center front hole in the helmet. Install the other screw (supplied with the kit) and one of the A-nuts into the center rear hole of the helmet. NOTE INSIDE CENTER FRONT A-NUT (SCREW ON OUTSIDE) If necessary, you may cut the front and rear hook tapes to fit between the retention screw holes as shown in Figure 2. Ensure that the inner surface of the helmet is clean before you install the hook tapes. Clean the surface with isopropyl alcohol if necessary. INSIDE CENTER REAR A-NUT (SCREW ON OUTSIDE) Figure 2. Installing Screws and A-Nuts 2 3. Referring to Figure 3, measure, mark (with a small dot), and attach the hook tapes as follows: a. Measure and mark the 1x4 crown area hook tape locations ¾ from the reference mark on both sides. Attach the tapes along the marked locations, centered vertically on each side of the reference mark. b. Measure and mark the 1x7 front hook tape location ¾ from the helmet edge beading (on TBH helmets) or 1-3/8 from the helmet edge beading (on Police Ballistic helmets). Attach top edge of the tape along the mark, and center the tape horizontally between the front retention screw holes. c. Measure and mark the 1x2 hook tape locations 3/8 from the front retention screw hole locations and ¾ from the edge beading (TBH helmets) or 1-3/8 from the edge beading (Police Ballistic helmets). Attach the tapes as shown. d. Measure and mark the 1x7 rear hook tape location 1-3/8 from the helmet edge beading. Attach the bottom edge of the tape along the mark, with the tape centered horizontally between the rear retention screw holes. e. Attach the 1x4.5 rear hook tapes as shown so that a triangular space is formed between these tapes and the 1x7 rear tape. 4. Reinstall the retention assembly.
EDGE BEADING FRONT 3/4 ON TBH (WITHOUT BEAK) 1-3/8 ON POLICE BALLISTIC HELMET (WITH BEAK) RETENTION SCREW HOLE REFERENCE MARK 3/4 RETENTION SCREW HOLE 3/8 3/8 3/4 ON TBH (WITHOUT BEAK) 1-3/8 ON POLICE BALLISTIC HELMET (WITH BEAK) 3/4 ON TBH (WITHOUT BEAK) 1-3/8 ON POLICE BALLISTIC HELMET (WITH BEAK) 3/4 TRIANGULAR SPACE RETEN- TION SCREW HOLE RETEN- TION SCREW HOLE 1-3/8 REAR Figure 3. Hook Tape Installation 3
Installing Pads NOTE Most kits have six bottom pads (three to be installed in front, three in rear). However, kit 00B11094-8 has eight bottom pads. The two extra bottom pads in kit 00B11094-8 are to be installed on the sides. Figure 4 shows the locations. 1. Install the pads as shown in Figure 4. As you install each pad, ensure that: the pad is firmly fastened to the attachment tapes you installed previously. the opening in each pad cover faces the inside surface of the helmet. 2. Don the helmet, and check the fit in accordance with Pages 5 and 6. Make any necessary adjustments. LOCATION OF EXTRA BOTTOM PAD (KIT 00B11094-8) BOTTOM PADS LOCATION OF EXTRA BOTTOM PAD (KIT 00B11094-8) CROWN PADS BOTTOM PADS OPENING IN COVER PADS PAD DETAIL Figure 4. Adjustable Pad Suspension System 4
Checking Fit of Helmet 1. Have the wearer don the helmet. Allow the helmet to settle on the head for a few minutes before checking the fit. 2. Ensure that the bottom sizing pads are just above the brow ridge. If the helmet is too high, have the wearer remove the helmet. Referring to Figure 5, adjust the height as follows: a. Remove the two crown pads, noting their position inside the helmet. b. Remove one or both 1/4-inch-thick foam pads from each crown pad cover. WARNING Ensure that all helmet adjustment mechanisms are properly adjusted for a snug, secure fit at all times when the helmet is worn. Failure to do so can result in an unstable helmet that will not protect the wearer. Each sizing pad contains one ½-inch-thick foam pad and two 1/4-inch-thick foam pads inside the cover. For impact protection and helmet stability, you must keep all ½-inch-thick foam pads inside the sizing pads and all sizing pads properly installed in the helmet when the helmet is worn. Remove the 1/4-inch-thick pads only where necessary to adjust the fit. c. Reinstall both crown pads (with the ½-inch-thick foam pad inside each one) in the helmet in the same positions from which they were removed. Ensure that the opening in each crown pad cover faces the top of the helmet. ¼-INCH- THICK FOAM PADS CROWN PADS ½-INCH- THICK FOAM PAD d. Have the wearer don the helmet. Recheck the helmet height. Continued on next page PAD DETAIL Figure 5. Crown Pads 5
3. Ensure that the helmet fit is snug and secure, yet comfortable. As needed, have the wearer remove the helmet, refer to Figure 6, and adjust the bottom pads as follows: a. Remove the bottom pads from the helmet as needed, noting their position inside the helmet. b. Remove one or both 1/4-inch-thick foam pads from each bottom pad cover. c. Reinstall the bottom pads (with the ½-inch-thick foam pad inside each one) in the helmet in the same positions from which they were removed. Ensure that the opening in each bottom pad cover faces the top of the helmet. d. Have the wearer don the helmet again. Recheck the fit. BOTTOM PADS BOTTOM PADS TWO 1/4-INCH- THICK FOAM PADS ONE ½-INCH-THICK FOAM PAD OPENING IN CLOTH COVER Figure 6. Bottom Pads 6
PARTS LIST Helmet Pad Kit, Part Number 00B11094-7 and 00B11094-8 HELMET PAD KIT 00B11094-7 Hook Fastener Tape, 1 x 7 Hook Fastener Tape, 1 x 4.5 Hook Fastener Tape, 1 x 4 Hook Fastener Tape, 1 x 2 Helmet Sizing Pad, TBH, Bottom 05D11980-1 6 ea. Helmet Sizing Pad, TBH, Crown 05D11980-2 2 ea. Screw, 3/8 75A3093-17 2 ea. Helmet Pad Kit Instruction Booklet TP0286 1 ea. HELMET PAD KIT 00B11094-8 Hook Fastener Tape, 1 x 7 Hook Fastener Tape, 1 x 4.5 Hook Fastener Tape, 1 x 4 Hook Fastener Tape, 1 x 2 Helmet Sizing Pad, TBH, Bottom 05D11980-1 8 ea. Helmet Sizing Pad, TBH, Crown 05D11980-2 2 ea. Screw, 3/8 75A3093-17 2 ea. Helmet Pad Kit Instruction Booklet TP0286 1 ea. 7
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TP0286 SEPTEMBER 2005