Operation Instructions PARAMASTER HIGH ALTITUDE LOW OPENING (PM HALO) HELMET ASSEMBLY 2012 Gentex Corporation
Contents SAFETY NOTICE............................ ii DESCRIPTION.............................. 1 Basic Helmet................................ 2 Optional Components........................... 4 SYSTEM CHECKOUT AND OPERATION............... 7 Helmet Fit Check.............................. 7 Attaching Snap-on Visor......................... 9 Attaching Step-in Visor.......................... 10 Stowing Helmet Communications Cable (Adjustable Pad Suspension Systems Only).............. 10 Attaching Eye-protective Goggles SORZ and SKYEYES...... 11 Operating Communications System.................. 12 Using Helmet Microphone with Down Lead Cable............... 13 Using 9" Mask Microphone Cable with Down Lead Cable.......... 14 Using 32" Mask Microphone Cable and Down Lead Cable with Switch... 16 Using Ear-To-Ear Cable............................. 18 INSPECTIONS............................. 21 Preflight Inspection......................... 21 Periodic Inspection......................... 22 CLEANING............................... 24 PARTS LISTS.............................. 26 Basic Helmet............................... 26 Optional Components.......................... 28 Available Radio Adapters........................ 31 For installation and maintenance procedures, refer to technical manual TP0347, which is available at www.gentexcorp.com. i
SAFETY NOTICE WARNING Proper fitting, operation, and maintenance of the helmet is imperative for the safety of the user. Before you use the helmet, read this entire manual thoroughly. Follow all Warnings and Cautions precisely. ii
DESCRIPTION The Paramaster High Altitude Low Opening (PM HALO) Helmet Assembly (Figure 1) incorporates the latest materials and processes. The helmet is lightweight, yet it affords maximum protection. It is also designed to provide unobstructed peripheral vision as well as ease of use with eye-protective goggles. The helmet conforms to Product Specification PS-0416 (effective February 2007) and has received safety confirmation from the U.S. Army TTC and the U.S. Air Force. The basic helmet includes a suspension system (adjustable pads or XLINER), a retention system, and earcups or leather earpads. Various optional components are available, including earphones, microphones, communications cables, alternative suspension systems, visors, goggles, and oxygen mask attachment hardware. This allows users to equip their helmets to fit their operational needs. This booklet includes a description of the basic helmet and optional components and includes instructions for general use and care. For installation and maintenance procedures, refer to technical manual TP0347, which is available from Gentex Corporation (www.gentexcorp.com). PART NUMBER 03D11801-1 Medium/Large with adjustable pads and earcup retention assembly PART NUMBER 03D11801-2 Medium/Large with adjustable pads and leather earpads PART NUMBER 04D11905-1 X-Large Wide with XLINER and earcup retention assembly PART NUMBER 04D11905-2 X-Large Wide with XLINER and leather earpads Figure 1. PM HALO Basic Helmet 1
Basic Helmet All basic helmets (Figure 2, next page) include the following components: Helmet shell. The outer surface of the helmet shell has a smooth finish (with non-reflective black paint) and is free of obstructions to prevent snagging of parachute lines. The helmet shell includes snaps for attachment of visors, bump stops to hold stowed visors in place, oblong eyelets though which goggle straps are threaded, pile fasteners to secure the goggle straps, and inside snaps for attachment of a communications cable on either side of the helmet. Edge roll. The leather-covered foam edge roll is reinforced in the front and rear of the helmet to facilitate attachment of night vision goggle strap assemblies. Chin strap. The chin strap is designed for a snug fit and helmet stability. It is attached to the helmet on both sides with attaching hardware. Nape strap. The adjustable nape strap provides stability and a snug fit at the back of the helmet. The differences among the basic helmets are as follows: Earcups. The helmet is supplied with one of two types of earcup systems: the plastic earcup retention assembly, in which the earcups are attached to the helmet shell with retention straps; or leather earpads, which attach to the inside of the helmet with hook and pile. Suspension systems. The helmet is supplied with one of two types of suspension systems: the adjustable pad suspension system, which provides ease of fitting and air circulation; or the XLINER, which provides ease of adjustment and simplified installation. Both systems are attached to hook fasteners on the energy-absorbing liner inside the helmet. NOTE: If the helmet has an adjustable pad suspension system, the nape strap is laced through back of the rear pad. If the helmet has an XLINER, the nape strap has a nape pad. The table below shows these differences for each helmet part number. Helmet Part Number Size Earcup Style Suspension Style 03D11801-1 Medium/Large Earcup Retention Assembly Adjustable Pads 03D11801-2 Medium/Large Leather Earpads Adjustable Pads 04D11905-1 X-Large Wide Earcup Retention Assembly XLINER (1/2-inch thick X-Large Wide) 04D11905-2 X-Large Wide Leather Earpads XLINER (1/2-inch thick X-Large Wide) 2
Bump stop* Visor snap* Helmet shell* Energyabsorbing liner* Cable snap (inside helmet)* Cable snap (inside helmet)* Pile fastener* Oblong eyelet* Edge roll* Nape strap* Chin strap* * Included on all helmets Adjustable pad suspension system 03D11801-1 Medium/Large Earcup retention assembly 04D11905-1 X-Large Wide Rear pad 03D11801-2 Medium/Large Earcup retention assembly Rear pad XLINER Nape pad 04D11905-2 X-Large Wide Leather earpad Leather earpad XLINER Nape pad Adjustable pad suspension system Figure 2. Basic Helmet Components 3
Optional Components The following optional components are available: Flex boom helmet microphone (Figure 3). Available in 150-ohm and 5-ohm versions, the microphone attaches to the helmet shell interior with attaching hardware. Earphones (Figure 4). Earphone options include 19-ohm, 19-ohm waterproof, 300-ohm, 600-ohm, 1000-ohm waterproof, and 1200-ohm waterproof. NOTE: For helmets with leather earpads, earphones with attached cords are required. Communications cables (Figure 5). Options include cables for use with an oxygen mask microphone and/or a helmet microphone. NOTE: Cables with 4-pin plugs are for use with single radio adapters. Cables with 5-pin plugs are for use with dual radio adapters. (Continued on next page) Figure 3. Microphone DOWN LEAD CABLE 03C11797-2 (Used with helmet microphone or mask microphone cable, 9" long) 4-pin plug (single radio) MASK MICROPHONE CABLE, 9" long, 69C2080-3 (Used with DOWN LEAD CABLE 03C11797-2 or -4) DOWN LEAD CABLE 03C11797-4 (Similar to cable 03C11797-2, but with 5-pin plug for dual radio adapters) 5-pin plug (dual radio) DOWN LEAD CABLE WITH SWITCH 03C11797-6 (Permits switching between helmet microphone and oxygen mask microphone; used with mask microphone cable, 32" long) Switch 4-pin plug (single radio) Figure 4. Earphones MASK MICROPHONE CABLE, 32" long, 69C2080-4 (Used with DOWN LEAD CABLE WITH SWITCH above) EAR-TO-EAR CABLE 03B11796-1 (Used with oxygen mask communications cable or DOWN LEAD CABLE WITH SWITCH below) Switch 4-pin plug (single radio) DOWN LEAD CABLE WITH SWITCH 06D12449-2 Figure 5. Cables 4
Mask attachment components (Figure 6). The following types are available: fixed bayonet receivers, mask snap adaptors, and a low profile bayonet system. Each type is provided in pairs along with attaching hardware. Suspension systems (Figure 7). Options include the thermoplastic liner (TPL ), the adjustable pad suspension (included with the Medium/Large basic helmets), and the XLINER (included with the X-Large Wide basic helmets). In addition, the XLINER is available for both helmet sizes in 1/2-inch and 3/4-inch thicknesses. Nape pad (Figure 8). The leather-covered foam nape pad (included with X-Large Wide helmets) is required for use with the XLINER and the TPL. (Continued on next page) WARNING If an XLINER or a TPL is installed into a helmet, ensure that a nape pad is installed on the nape strap. Failure to do so could result in injury. XLINER and TPL are registered trademarks of Gentex Corporation. Fixed bayonet receiver kit Anti-snag bayonet receiver kit Mask snap adapter kit Figure 6. Mask Attachment Components TPL Adjustable pad suspension Anti-snag bayonet receiver kit, no receivers Figure 7. Suspension Systems Figure 8. Nape Pad XLINER 5
Snap-on visors (Figure 9). Snap-on visors are snapped directly to the helmet. Visors are available with an MBU-12/P trim or an MBU-20/P trim and in clear or sunshade. Visor cover (Figure 9). The visor cover protects the snap-on visors in the stowed position. The cover attaches to the visor with hook-and-pile fasteners. Sunshade visor Clear visor Visor cover Figure 9. Snap-on Visors and Visor Cover Step-in visor (Figure 10). The step-in visor is designed to be worn between the eyes and the night vision goggles. Like the snap-on visors, the step-in visor is snapped directly to the helmet and is available with an MBU-12/P trim or an MBU-20/P trim. The standard step-in visor is clear; a neodymium version is also available. Figure 10. Step-in Visor Modified SORZ goggle Eye-protective goggles (Figure 11). The following types are available: the modified SORZ (with clear, sunshade, or amber lenses) and the modified SKYEYES (with clear or sunshade lenses). Figure 11. Eye-protective Goggles Modified SKYEYES goggle 6
SYSTEM CHECKOUT AND OPERATION Perform system checkout to ensure that your helmet is in good operating condition. System checkout tasks include checking the fit of the helmet, performing an operational check of the communications system, attaching the oxygen mask and visors as required, and reporting any problems to your maintenance technician. Helmet Fit Check Check the fit of the helmet, keeping in mind the following WARNING and CAUTION notices. 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. If the helmet has an XLINER or a TPL, ensure that a nape pad is installed on the nape strap. Failure to do so could result in injury. CAUTION When donning or doffing the helmet, flex the helmet just enough to allow sufficient clearance for the head. Excessive flexing may damage the helmet. NOTES: Helmet size Medium/Large is designed to fit 85 percent of the population. Personnel with hat sizes 7-5/8 or larger may require helmet size X-Large Wide. Figure 12 (next page) shows a helmet with an adjustable pad suspension system. However, this procedure also applies to helmets with all other suspension systems (XLINER and TPL). 1. Don the helmet as follows: a. Grip the helmet with thumbs hooked in the earcups (Figure 12, next page), and flex the helmet slightly to clear the head. b. Place the front edge of the helmet against the forehead. c. Rotate the helmet toward the rear and down onto the head. Ensure that the edgeroll is positioned just out of the aircrew member s line of sight as the aircrew member looks upward. d. Allow the helmet to settle on the head for a few minutes before checking the fit. (Continued on next page) 7
2. Adjust the nape strap (Figure 13) for a snug fit. Attach the end of the nape strap to the pile fastener. 3. Buckle the chin strap (Figure 14) and adjust it for a snug fit. Attach the end of the chin strap to the pile fastener on the chin pad. 4. Evaluate the fit as follows: a. Overall helmet fit: The helmet should be snug and secure, yet comfortable. Attempt to rock the helmet back and forth on your head, the helmet should not move. If you experience any problems with the overall fit, notify your maintenance technician. Figure 12. Grip for Donning Helmet b. Helmet height: Ensure that the edgeroll is just above the eyebrows; this is the correct height. If the helmet is too high or too low, notify your maintenance technician. c. Earcup position: Ensure that the earseals completely surround the ears; this is the correct earcup position. If the earcup position is incorrect, notify your maintenance technician. End of nape strap Figure 13. Nape Strap Chin pad Buckle End of chin strap Figure 14. Chin Strap 8
Attaching Snap-on Visor Referring to Figure 15, do the following: 1. Attach the visor by stretching the end of the strap slightly past the helmet snap and fastening the visor snap to the the helmet snap from front to back. Repeat for the other strap. 2. Adjust the visor straps for a snug fit to the helmet by moving the slide adjustments as needed. 3. Lower and raise the visor by grasping it in the middle, pulling it slightly away from the helmet, and moving it down or up as needed. Ensure that the top edge of the visor is against the bump stops when the visor is raised. 4. To remove the visor, grasp the end of the strap and pull it away from the helmet snap from back to front. 5. If you are using the visor cover, do the following: a. Raise the visor. b. Attach the hook fasteners on the underside of the visor cover to the pile fasteners on the visor. Visor cover Slide adjustment Visor snap Pile fastener Bump stop Helmet snap Figure 15. Snap-on Visor 9
Attaching Step-in Visor 1. Don the helmet. 2. Referring to Figure 16, do the following: a. Snap the step-in visor to the helmet on both sides. b. Adjust the straps for a snug fit by moving the slide adjustments on both sides. Slide adjustment Visor snap 3. Position the night vision device over the step-in visor. Helmet snap Figure 16. Step-in Visor Stowing Helmet Communications Cable (Adjustable Pad Suspension Systems Only) Helmets with adjustable pad suspension system: Fold the cable and stow it under the hook fastener tab on the back of the rear suspension pad (Figure 17 ). Helmets with XLINER or TPL: Stow the cable inside your clothing as directed by your supervisor. Cable Hook fastener Figure 17. Communications Cord Stowed 10
Attaching Eye-protective Goggles SORZ and SKYEYES 1. Before donning the helmet, insert the strap ends through the slots in the back of the helmet (Figure 18) with the goggle hanging loosely at the front of the helmet. Figure 18. Straps Inserted Through Slots 2. Don the helmet. 3. Pulling the strap ends further through the slots, bring the goggle into place on the face until it fits snugly as shown in Figure 19. Figure 19. Goggle in Place 4. Attach the strap ends to the pile fastener strip at the back of the helmet as shown in Figure 20. 5. Stow the goggle atop the helmet as shown in Figure 21. Figure 20. Strap Ends Attached Figure 21. Goggle Stowed 11
Operating Communications System Depending on the communications components with which your helmet is equipped, shown in Figure 22, you will operate the communications system in one of the following ways: Using the helmet microphone with the down lead cable. Refer to Page 13. Using the 9" oxygen mask microphone cable with the down lead cable. Refer to Pages 14-15. Using the 32" oxygen mask microphone cable with the down lead cable with switch. Refer to Pages 16-17. Using the ear-to-ear cable. Refer to Pages 18-20. Using helmet microphone with down lead cable Using 9" mask microphone cable with down lead cable Using 32" mask microphone cable with down lead cable with switch Using ear-to-ear cable (can be used in one of three ways) Figure 22. Helmet Communications Components 12
Using Helmet Microphone with Down Lead Cable Ensure that your maintenance technician has checked your communications system with the testing device. With the helmet properly donned and fitted, and all straps properly fastened and adjusted, refer to Figure 23 and do the following: 1. Don the helmet, adjust the nape strap, and fasten and adjust the chin strap as described on Pages 7 and 8. 2. Bend the boom to adjust the microphone in front of your lips. 3. Connect the down lead cable to your communications device. Microphone Down lead cable NOTE: Down lead cable with 4-pin plug (03C11797-2) is for use with single radio PTT adapters. Downlead cable with 5-pin plug (03C11797-4) is for use with dual radio PTT adapters. Refer to the cable adapter list at the end of this booklet for more information. To communications device 4-pin plug (single radio) 5-pin plug (dual radio) Figure 23. Microphone and Communications Cord 13
Using 9" Mask Microphone Cable with Down Lead Cable NOTE: Before you begin, ensure that the appropriate bayonet receiver kit is installed on your helmet and that the helmet and the oxygen mask have been properly fitted. 1. Referring to Figure 24, unplug the helmet microphone from the communications cord connector. 2. Referring to Figure 25, stow the helmet microphone inside the notch of the energy-absorbing liner in the helmet. 3. Referring to Figure 26, plug one end of the mask microphone cord into the down lead cable connector. Figure 24. Unplugging Microphone Energy-absorbing liner Down lead cable connector Microphone Microphone plug 4. If not already done, attach the visor to the helmet as described on Page 9. 5. Don the helmet, adjust the nape strap, and fasten and adjust the chin strap as described on Pages 7 and 8. (Continued on next page) Figure 25. Microphone Stowed Inside Helmet Down lead cable connector Mask microphone cable Down lead cable Figure 26. Connecting Down Lead Cable to Mask Microphone Cable 14
6. Referring to Figure 27, do the following: Visor a. Attach the mask by inserting the mask bayonets into the bayonet receivers to the fourth locking position. b. Lower the visor to check the interface between the visor and the mask. Bayonet Bayonet receiver 7. Referring to Figure 28, do the following: Figure 27. Attaching Oxygen Mask a. Plug the other end of the mask microphone cable to the oxygen mask microphone. b. Connect the down lead cable to your communications device. NOTE: Down lead cable with 4-pin plug (03C11797-2) is for use with single radio PTT adapters. Downlead cable with 5-pin plug (03C11797-4) is for use with dual radio PTT adapters. Refer to the cable adapter list at the end of this booklet for more information. Mask microphone Mask microphone cable Down lead cable To communications device 4-pin plug (single radio) 5-pin plug (dual radio) Figure 28. Connecting Down Lead Cable to Mask Microphone 15
Using 32" Mask Microphone Cable and Down Lead Cable with Switch This configuration allows you to switch from the helmet microphone to the oxygen mask microphone without unplugging the helmet microphone inside the helmet. Do the following: 1. To use the helmet microphone (Figure 29): a. Don the helmet, adjust the nape strap, and fasten and adjust the chin strap as described on Pages 7 and 8. b. Bend the boom to adjust the helmet microphone in front of your lips. c. Set the down lead cable switch to BOOM. d. Connect the down lead cable to your communications device. (Continued on next page) Microphone VIEW OF SWITCH Down lead cable NOTE: This down lead cable (03C11797-6) has a 4-pin plug. Use this cable with single radio PTT adapters. Refer to the cable adapter list at the end of this booklet for more information. To communications device 4-pin plug (single radio) 16 Figure 29. Using Helmet Microphone and Down Lead Cable with Switch
2. To use the mask microphone: a. Referring to Figure 30, stow the microphone inside the helmet. b. Don the helmet, adjust the nape strap, and fasten and adjust the chin strap as described on Pages 7 and 8. c. Referring to Figure 31, connect one end of the mask microphone cable to the receptacle on the down lead cable connector. d. Referring to Figure 31, set the down lead cable switch to MASK. e. Attach the mask by inserting the mask bayonets into the bayonet receivers to the fourth locking position. Lower the visor to check the interface between the visor and the mask. f. Referring to Figure 31, connect the other end of the mask microphone cable to the mask microphone. g. Connect the down lead cable to your communications device. NOTE: This down lead cable (03C11797-6) has a 4-pin plug. Use this cable with single radio PTT adapters. Refer to the cable adapter list at the end of this booklet for more information. Figure 30. Microphone Stowed Inside Helmet Mask microphone Mask microphone cable Receptacle on down lead cable connector To communications device Microphone Figure 31. Connecting Cord to Mask Microphone VIEW OF SWITCH 17
Using Ear-To-Ear Cable You can use the ear-to-ear cable in one of the following ways: (1) with an oxygen mask that has its own communications cable, (2) with a down lead cable with switch (06D12449-2) and a helmet microphone, or (3) with the same down lead cable and a 32" mask microphone cable. Do the following: 1. To use the ear-to-ear cable with an oxygen mask that has its own communications cable (Figure 32): a. Don the helmet, adjust the nape strap, and fasten and adjust the chin strap as described on Pages 7 and 8. b. Attach the mask by inserting the mask bayonets into the bayonet receivers to the fourth locking position. c. Referring to Figure 32, connect the mask communications cable lead to the ear-to-ear cable connector at the back of the helmet. (Continued on next page) Mask communications cable lead Ear-to-ear cable BACK VIEW Mask communications cable lead Figure 32. Using Helmet with Ear-to-Ear Cable 18
2. To use the ear-to-ear cable with the down lead cable with switch and the helmet microphone (Figure 33): a. Don the helmet, adjust the nape strap, and fasten and adjust the chin strap as described on Pages 7 and 8. b. Bend the boom to adjust the helmet microphone in front of your lips. c. Set the down lead cable switch to BOOM. d. Connect the down lead cable to your communications device. NOTE: This down lead cable (06D12449-2) has a 4-pin plug. Use this cable with single radio PTT adapters. Refer to the cable adapter list at the end of this booklet for more information. (Continued on next page) Microphone VIEW OF SWITCH Down lead cable To communications device 4-pin plug (single radio) Figure 33. Using Helmet Microphone and Down Lead Cable with Switch 19
3. To use the ear-to-ear cable with the down lead cable with switch and the 32" mask microphone cable: Microphone a. Referring to Figure 34, stow the microphone inside the helmet. b. Don the helmet, adjust the nape strap, and fasten and adjust the chin strap as described on Pages 7 and 8. c. Referring to Figure 35, connect one end of the 32" mask microphone cable to the receptacle on the down lead cable connector. d. Referring to Figure 35, set the down lead cable switch to MASK. e. Attach the mask by inserting the mask bayonets into the bayonet receivers to the fourth locking position. Lower the visor to check the interface between the visor and the mask. f. Referring to Figure 35, connect the other end of the mask microphone cable to the mask microphone. g. Connect the down lead cable to your communications device. NOTE: This down lead cable (06D12449-2) has a 4-pin plug. Use this cable with single radio PTT adapters. Refer to the cable adapter list at the end of this booklet for more information. Figure 34. Microphone Stowed Inside Helmet Mask microphone Mask microphone cable Receptacle on down lead cable connector To communications device Figure 35. Connecting Cord to Mask Microphone VIEW OF SWITCH 20
INSPECTIONS Preflight, postflight, and periodic inspections are required to ensure that the helmet is in proper operating condition. The user shall perform preflight inspections. The maintenance technician shall perform postflight inspections (see technical manual TP0347). The user is responsible for ensuring that the maintenance technician has performed periodic inspections. Preflight Inspection Prior to each flight, the user shall inspect the helmet to determine that it is in serviceable condition and report any deficiencies to the maintenance technician. Do the following: 1. Ensure that the helmet, earcups and oxygen mask are properly fitted. 2. Check the helmet shell for evidence of damage such as cracks, warping, or chipped paint. NOTE: A hairline crack is defined as a fine crack which has broken the paint surface, but has not necessarily broken through the layers of the helmet material. Any crack that has penetrated through the helmet material will affect the integrity of the helmet and therefore the helmet should be condemned and disposed of. 3. Ensure that the chin strap and nape strap are properly adjusted and that the screws are securely attached to the helmet shell. 4. Ensure that the visors and goggles are free from cracks, scratches, dust, and smears. Minor scratches not interfering with the critical vision area are permissible. 5. Ensure that all communications components are securely attached and that the headset/microphones operate properly. This check may be performed by plugging the microphone cable and plug assembly into MQ-1/MQ-1A tester, DMH-1, or service-approved tester. Speak into the microphone. The microphone and earphones are operating properly when the voice is transmitted from the microphone through the amplifier and is heard in the headset. 6. Check the energy absorbing liner and the suspension system (fitting pads, XLINER, or TPL) for looseness, improper fit, holes, cracks, or torn fabric. 7. Check the general condition of all attaching hardware and components. 8. Inspect the oxygen mask and associated components for general condition as required by the applicable technical order. 21
Periodic Inspection Operating personnel shall be responsible for ensuring that their helmets have been inspected, cleaned and repaired as required by qualified equipment technicians within the last 30 days prior to each flight. Helmets that are not managed as integrated systems in conjunction with the oxygen mask may be inspected at a 90-day inspection interval. Inspections shall be annotated on a suitable inspection record, and suitable pressure sensitive-tape attached to the helmet or mask assembly, and/or as described by service directives. NOTE: As a result of this inspection, any component found to be defective will be repaired/replaced as necessary. Report any deficiencies to the maintenance technician. SERVICE OPTION: Helmets (with the oxygen mask) used very infrequently and carried on board the aircraft for emergency use, require inspection not to exceed 90 days. Services will determine what constitutes infrequently used (this should be specified service directives). 1. Visually the inspect helmet shell for cleanliness, warping, holes, cracks and scratches. 2. Inspect the leather edgeroll for holes, cuts, torn seams or detached areas. 3. Inspect the bump stops for damaged and detached areas. 4. Inspect the suspension system (fitting pads, XLINER, or TPL) as follows: a. Note how the suspension system is installed in the helmet; then remove the suspension system from the helmet. b. Examine the hook fasteners on the energy-absorbing liner, ensuring that the fasteners are securely adhered. c. Examine the energy-absorbing liner for damaged areas such as gouges, depressions, or evidence of erosion due to attack by solvents. Replace the liner if there is reasonable assumption that head protection will be compromised due to the extent of liner damage. d. Examine the suspension system. Fitting pads: Examine for loosening of cemented parts (leather lining, pile backing, pile fasteners); torn fabric or seams; excessive soil. XLINER: Examine for torn fabric, separated seams, and excessive soil. Also, ensure that the XLINER is the correct size for the helmet. TPL (optional item): Inspect the cover for cleanliness and security of attachment to the layers. (Continued on next page) 22
5. Inspect the communications components as follows: a. Inspect the ear cushions for secure attachment to earcups, cleanliness, cuts, tears or evidence of compression set and hardening. b. Inspect earcups or leather earpads for breakage or other damage that could impair safety or sound attenuation. c. Inspect cords for breaks or frayed areas. d. Plug the microphone cable and plug assembly into the MQ-1/MQ-1A or DMH-1 tester and assure that the microphone and earphones are working properly. Speak into the microphone. The microphone and earphones are operating properly when the voice is transmitted from the microphone through the amplifier and heard in the headset. 6. Inspect the visors and goggles as follows: NOTE: Visors and goggles are not required for altitude chamber student training use. a. Inspect the straps to ensure that the nylon webbing and cotton elastic are not frayed or torn and that snap fasteners or hook/pile fasteners are all in good working condition. b. Visually inspect the visor snap fasteners for proper clinching of the fastener components. The roll barrels in each snap socket and stud must be rolled over all around. They should have a symmetrical, donut-shaped appearance. Any fastener on which the barrel material is not completely rolled over the edge of the stud or socket must be discarded. Any roll with more than three splits that extend over the top of the barrel and are readily detectable by visual observation shall be regarded as defective. c. Inspect the rubber edge beading at the top the visor lens for unbonded sections, cuts, tears, or holes. d. Inspect visor/goggle lens for cracks, scratches, dust particles and smears. If visors are scratched, replace as necessary. Minor scratches not interfering with critical vision area are permissible. 7. Inspect the nape strap and the chin strap for cleanliness and to ensure that the fabric and stitching are not frayed or torn; the buckles on the chin strap and the nape strap are not corroded, bent, or broken; the retainer screws in the chin strap and the nape strap are securely attached and are not corroded; and the washers are properly positioned. (Continued on next page) 23
8. Inspect the bayonet receivers as follows: CAUTION Do not use thread-locking adhesive on the bayonet receiver screws. The spacers will be damaged if they come into contact with thread-locking adhesive. a. Inspect the spacers for cracks or deterioration. b. Ensure that the screws are securely tightened and that the lock washers are installed. c. Ensure that the receivers were installed with the part number facing the helmet shell. 9. Inspect the helmet visor snaps as follows: a. Inspect the snap screws for corrosion and tightness. Assure that the helmet is thoroughly cleaned and serviceable before returning to user. b. Check the snaps for security and proper installation of lock washer, part number MS35335 58. CLEANING 1. Helmet Shell. Clean the helmet shell as follows: a. Wash the helmet shell using a mild detergent and a lint-free cloth dampened with water. Mild abrasive scouring powder or soft-scrubbing cleanser may be used to remove stains or scuff marks. b. Wipe the helmet shell clean using a water-dampened cloth to remove detergents. 2. Nape Strap Assembly. Clean the nape strap assembly as follows: a. Lightly sponge with a mild solution of detergent and water. b. Wipe with a damp, lint-free cloth. 3. Adjustable Pad Suspension. Clean the adjustable pad suspension as follows: a. Remove the pads from the helmet. b. Remove the foam pads from the covers. c. Hand wash the covers and foam pads and allow them to air dry. d. Reinstall the foam pads into the covers. e. Reinstall the adjustable pad suspension system into the helmet. f. Don the helmet and check the fit as described on Pages 7 and 8. (Continued on next page) 24
4. TPL Assembly. Clean TPL assembly as follows: a. Remove the cloth cover from the plastic layer assembly. b. Clean the cover by hand washing with a mild solution of detergent and water. c. Thoroughly rinse the cover in clear water and allow it to air dry. d. Apply new double-sided vinyl tape to the cover, and reinstall the cover on the plastic layer assembly. e. Reinstall the foam pads into the covers. Don the helmet and check the fit as described on Pages 7 and 8. 5. XLINER. Clean the XLINER as follows: a. Remove the XLINER from the helmet. b. Hand-wash the XLINER with mild detergent; rinse thoroughly and allow to dry flat. Observe the following precautions: Do not place in dryer. Do not wring. Do not use bleach or machine detergents. c. Reinstall the XLINER. d. Don the helmet and check the fit as described on Pages 7 and 8. 6. Communications Components. Wipe with a damp cloth. 7. Visor Assemblies. Clean the visor assemblies with a soft, clean, lint-free cloth dampened with a 70 percent isopropyl alcohol solution or equivalent. 8. Goggle Assemblies. Clean the goggle assemblies with a soft, clean cloth dampened with water. Allow to air dry. 9. Leather Edgeroll. Clean the leather edgeroll with a moistened gauze pad and saddle soap to remove dirt. Rinse with a moist gauze pad and allow to air-dry. 25
PARTS LISTS Following are the parts lists for the PM HALO helmet. Pages 26 and 27 show parts for the basic helmet. Pages 28-30 show optional components. Pages 31-35 show available adapters For more information, contact Gentex Corporation, P.O. Box 315, Carbondale, PA 18407, phone (570)282-3550, fax (570)282-8555. Visit our web site at gentexcorp.com. Basic Helmet Adjustable pad suspension Earcup retention assembly Nape strap Chin strap Chin pad Leather earpad Figure 36. PM HALO Basic Helmet, Medium/Large (For X-Large Wide, see Figure 37 on next page) Helmet Assembly, PM HALO, Medium/Large, with Plastic Earcups 03D11801-1 Earcup Retention Assembly 03D11800-2 1 ea. Chin Strap 09A12914-4 1 ea. Chin Pad 89C7764-1 1 ea. Nape Strap 03B11793-1 1 ea. Spacer Pad Set (Not shown) 67B1721 1 ea. Adjustable Pad Suspension Kit 02B11587-4 1 ea. Instruction Booklet TP0257 1 ea. Helmet Assembly, PM HALO, Medium/Large, with Leather Earpads 03D11801-2 Leather Earpad Set 79C4473-4 1 ea. Chin Strap 09A12914-4 1 ea. Chin Pad 89C7764-1 1 ea. Nape Strap 03B11793-1 1ea. Spacer Pad Set (Not shown) 67B1721 1 ea. Adjustable Pad Suspension Kit 02B11587-4 1 ea. Instruction Booklet TP0257 1 ea. 26
XLINER Earcup retention assembly Nape pad Nape strap Chin strap Chin pad Leather earpad Figure 37. PM HALO Basic Helmet, X-Large Wide (For Medium/Large, see Figure 36 on previous page) Helmet Assembly, PM HALO, X-Large Wide, with Plastic Earcups 04D11905-1 Earcup Retention Assembly 03D11800-2 1 ea. Chin Strap 09A12914-4 1 ea. Chin Pad 89C7764-1 1 ea. Nape Strap 03B11793-1 1 ea. Nape Pad 88C7503 1 ea. Spacer Pad Set (Not Shown) 67B1721 1 ea. XLINER 05D11925-7 1 ea. Instruction Booklet TP0257 1 ea. Helmet Assembly, PM HALO, X-Large Wide, with Leather Earpads 04D11905-2 Earpad Set 79C4473-4 1 ea. Chin Strap 09A12914-4 1 ea. Chin Pad 89C7764-1 1 ea. Nape Strap 03B11793-1 1ea. Nape Pad 88C7503 1 ea. Spacer Pad Set (Not Shown) 67B1721 1 ea. XLINER 05D11925-7 1 ea. Instruction Booklet TP0257 1 ea. 27
Optional Components Microphones (Figure 38) Flex boom, 150-ohm: 04B11827-1 Flex boom, 5-ohm: 04B11827-2 Earphones (Figure 39) 19-ohm: 69B2032 19-ohm waterproof: 73B2619 300-ohm: 75B3195 600-ohm: 78A3981 1000-ohm waterproof: 71B2383 1200-ohm waterproof: 90A7929 Cables (Figure 40) Down lead cable (single radio): 03C11797-2 (U-174/U connector) Down lead cable (dual radio): 03C11797-4 (U-384/U connector) Down lead cable with switch: 03C11797-6 Mask microphone cable, 9" long: 69C2080-3 Mask microphone cable, 32" long: 69C2080-4 Ear-to-ear cable: 03B11796-1 Down lead cable with switch: 06D12449-2 Continued on next page Figure 38. Microphone Figure 39. Earphones DOWN LEAD CABLE 03C11797-2 (Used with helmet microphone or mask microphone cable, 9" long) 4-pin plug (single radio) MASK MICROPHONE CABLE, 9" long, 69C2080-3 (Used with DOWN LEAD CABLE 03C11797-2 or -4) DOWN LEAD CABLE 03C11797-4 (Similar to cable 03C11797-2, but with 5-pin plug for dual radio adapters) 5-pin plug (dual radio) DOWN LEAD CABLE WITH SWITCH 03C11797-6 (Permits switching between helmet microphone and oxygen mask microphone; used with mask microphone cable, 32" long) Switch 4-pin plug (single radio) MASK MICROPHONE CABLE, 32" long, 69C2080-4 (Used with DOWN LEAD CABLE WITH SWITCH above) EAR-TO-EAR CABLE 03B11796-1 (Used with oxygen mask communications cable or DOWN LEAD CABLE WITH SWITCH below) Switch 4-pin plug (single radio) DOWN LEAD CABLE WITH SWITCH 06D12449-2 Figure 40. Cables 28
Oxygen Mask Receivers (Figure 41) Glass beaded receiver kit: 82A5614-20 Fixed bayonet receiver kit: 93A8514 Mask snap adapter kit: 91A8084-1 Anti-snag bayonet receiver kit: 05A12024-2 Anti-snag bayonet receiver kit, no receivers: 05A12024-1 Suspension Systems (Figure 42) TPL Kit, Medium/Large: 85D7087-2P TPL Kit, X-Large Wide: 85D7087-30P Adjustable Pad Suspension: 02B11599-2 (Included with Medium/Large PM HALO Helmet) XLINER, Medium/Large ½" Thick: 05D11925-3 XLINER, Medium/Large ¾" Thick 05D11925-4 XLINER, X-Large Wide ½" Thick 05D11925-7 XLINER, X-Large Wide ¾" Thick: 05D11925-8 Nape Pad (Figure 43) 88C7503 Continued on next page Bayonet receiver kit (Glass beaded or fixed) Anti-snag bayonet receiver kit Figure 41. Mask Attachment Components TPL Adjustable pad suspension Figure 42. Suspension Systems Figure 43. Nape Pad Mask snap adapter kit Anti-snag bayonet receiver kit, no receivers XLINER 29
Snap-on Visors (Figure 44) MBU-12/P Trim Clear: 81D5189-3 MBU-12/P Trim Sunshade: 81D5189-4 MBU-20/P Trim Clear: 91A8058-6 MBU-20/P Trim Sunshade: 91A8058-7 Visor cover 85C7049-1 Step-in Visors (Figure 45) MBU-12/P trim, clear, Medium: 01C11448-1 MBU-12/P trim, clear, Large/X-Large: 01C11448-3 MBU-20/P trim, clear, Medium: 01C11176-1 MBU_20/P trim, clear, Large/X-Large: 01C11176-3 Goggles (Figure 46) SORZ (modified) Clear: 03B11806-1 SORZ (modified) Sunshade: 03B11806-2 SORZ (modified) Amber: 03B11806-3 SKYEYES (modified) Clear: 03B11805-1 SKYEYES (modified) Sunshade: 03B11805-2 Sunshade visor Clear visor Figure 44. Snap-on Visors and Visor Cover Figure 45. Step-in Visors Visor cover Modified SORZ goggle Modified SKYEYES goggle Figure 46. Eye-protective Goggles 30
Available Radio Adapters Adapters are available for various aircraft and man-worn radios, including USAF, U.S. Army helos, PRC-148, SINGCARS, SABER, and others. Typical adapters are shown in on Pages 31 through 35. Contact Gentex Corporation for more information. Single Radio Adapters (Figure 47) for use with downlead cables 03C11797-2 and 03C11797-6 (4-pin U-174/U) 05B12186-2 Lower cable with AMP and PTT for Motorola HT 1000 radios 05B12186-4 Lower cable with PTT for Motorola HT 1000 radios (no AMP) 00D11022-1 Lower cable with PTT and Urban MBITR with remote finger PTT option 00D11022-2 Lower cable with PTT and Maritime MBITR with remote finger PTT option 07C12593-1 Lower cable with PTT for Motorola HT 1000 radios with remote PTT option 03C11762-1 Lower cable with PTT for Saber Expo (6-pin connector) with remote PTT option 07D12626-1 Lower cable with PTT and Urban MBITR (no remote finger PTT option) 07D12626-2 Lower cable with PTT and Maritime MBITR (no remote finger PTT option) 07D12626-3 Lower cable with PTT; AP-107 connector Figure 47. Single Radio Adapters for Cables 03C11797-2 and 03C11797-6 31
Single Radio Adapters (Figure 48) for use with downlead cable 03C11797-4 (5-pin U-384/U) 05B12186-1 Lower cable with AMP and PTT for Motorola HT 1000 radios 05B12186-3 Lower cable with PTT for Motorola HT 1000 radios (no AMP) 04C11824-1 Adapter U-385/U with PTT; connects to PRC-148 Urban MBITR; single radio only 04C11824-2 Adapter U-385/U with PTT; connects to PRC-148 Maritime MBITR; single radio only 05C12231-1 Lower cable with PTT and remote PTT; accepts U-384 to Urban MBITR 05C12231-2 Lower cable with PTT and remote PTT; accepts U-384 to Maritime MBITR 05C12231-3 Lower cable with PTT and remote PTT; accepts U-384 to AP107 07C12593-1 Lower cable with PTT and remote PTT option for Motorola HT 1000 radios 00B11020-1 Remote finger PTT with single-button ON/OFF Figure 48. Single Radio Adapters for Cable 03C11797-4 32
Dual Radio Adapters (Figure 49) for use with downlead cable 03C11797-4 (5-pin U-384/U) 02C11626-1 Lower cable with dual PTT 03C11699-1 Lower cable with dual PTT (interfaces with remote PTT) 03B11700-1 Remote dual radio PTT with two buttons Figure 49. Dual Radio Adapters for Cable 03C11797-4 Dual Radio Adapters (Figure 50) for use with lower cable 03C11699-1 or 02C11626-1 (dual radio PTT) 03C11719-1 Adapter for Urban MBITR PRC-148; extends 2 feet 03C11719-2 Adapter for Urban MBITR PRC-148; extends 4 feet 01B11428-1 Adapter for Maritime MBITR PRC-148 01B11429-1 Adapter for AIC-10 intercom 07C12592-1 Adapter with pre-amp for Motorola HT 1000 radios 97D9975-6 Adapter for Motorola HT 1000 radios 06C12301-2 Adapter with pre-amp that converts AJ107 to U-174/U Figure 50. Dual Radio Adapters for Cable 03C11699-1 or 02C11626-1 33
Specialty Adapters (Figure 51) 05B12197-1 Adapter that converts 4-pin U-174/U to 5-pin U-385/U 05B12197-2 Adapter with pre-amp that converts 4-pin U-174/U to 5-pin U-385/U 06C12301-1 Adapter with pre-amp that converts 5-pin U-384/U to 4-pin U-174/U 06C12301-3 Adapter with pre-amp that converts U-384/U to U-385/U 09C13036-1 Extension cable that converts single U-384/U to dual U-385/U 09C13037-1 Extension cable that converts U-384/U to U-385/U 00B11046-1 Adapter that converts 5-pin U-384/U to 4-pin U-174/U on cable 03C11797-4 Figure 51. Specialty Adapters Cables Wired for Peltor PTT Assemblies (Figure 52) 06D12539-2 Upper cable with U-174/U similar to 03C11797-2 06D12539-4 Upper cable with TPSJ-101 similar to 03C11797-6 34 06D12538-2 Upper cable with TPSJ-101 similar to 06D12449-2 Figure 52. Cables for Peltor PTT
Breakaway Cables (Figure 53) 08A12803-1 Breakaway version of 03C11797-2 08A12803-2 Breakaway version of 03C11797-4 08A12803-3 Breakaway version of 03C11797-6 Figure 53. Breakaway Cables 35
TP0257 REV. 4 FEBRUARY 2012