Gentex HGU-56/P Operation And Maintenance Instructions Download Page 1

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Operation and Maintenance Instructions

HGU-56/P COMMERCIAL

HELMET ASSEMBLY

2010 GENTEX Corporation

Summary of Contents for HGU-56/P

Page 1: ...Operation and Maintenance Instructions HGU 56 P COMMERCIAL HELMET ASSEMBLY 2010 GENTEX Corporation...

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Page 3: ...ngs and Cautions precisely When you replace components or install additional components on Gentex products always use genuine factory new Gentex parts This will ensure a correct fit and maintain the s...

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Page 5: ...Installing Optional ANVIS Dual Visor Assemblies Quick Disconnect or Direct Mount 9 2 3 3 Installing ANVIS Attachment Kit for Quick Disconnect ANVIS Dual Visor Assembly 10 2 3 4 Installing ANVIS Attach...

Page 6: ...3 3 1 TPL or SCL Cloth Cover 48 3 3 2 Energy Absorbing Liner 49 3 3 3 Retention Assembly 51 3 3 4 Earcups or Earphones 53 3 3 5 Microphone Boom Cord Swivel Assembly Wire Boom 55 3 3 6 Flex Boom Micro...

Page 7: ...erating the helmet properly Section 3 Maintenance This section includes information for cleaning troubleshooting performing preventive maintenance and replacing components Section 4 Parts List This se...

Page 8: ...Liner TPL Optimizes fit and comfort can be heat softened and custom fitted if necessary Energy Absorbing EA Liner Absorbs and reduces impact forces Dual Visor Assembly Protects the wearer s eyes from...

Page 9: ...ng in low light conditions such as snowy foggy overcast hazy or cloudy environments causes the blue portions of the visible spectrum to appear black or dark while other colors appear nearly normal ava...

Page 10: ...d the helmet bag 2 Unseal the bag containing the helmet Take the helmet the earcup spacer pad set the headband fitting pad set and the ANVIS mounting kit if supplied out of the bag Remove the wrapping...

Page 11: ...fastener running vertically to a wall bottom of the strip approximately 5 feet 4 inches above the floor so that the block can be adjusted for the various heights of user s heads 2 Attach the block of...

Page 12: ...marker make a small mark at this point in the center of the wearer s forehead this is the forehead reference point FRP 5 Referring to Figure 2 2 View B use a combination square to measure from the FR...

Page 13: ...or Assembly Paragraph 2 3 4 Page 12 Installing High Contrast Visor Paragraph 2 3 5 Page 16 Installing Flex Boom Microphone Paragraph 2 3 6 Page 18 Installing 36 Coiled Communications Cord Paragraph 2...

Page 14: ...from the helmet 2 Referring to Figure 2 4 place the SCL in the helmet 3 Ensure that the holes in the SCL are aligned with the holes in the energy absorbing liner as shown in Figure 2 5 The SCL should...

Page 15: ...al visor assembly on the helmet 2 Lift the entire existing dual visor assembly away from the helmet and set aside 3 Align the thumbscrews of the ANVIS dual visor assembly over the four posts protrudin...

Page 16: ...e rear of the mount so that the screw holes line up and the plate is flush with the top and bottom rear of the mount Ensure that the wires extending from the rear of the mount are aligned in the mount...

Page 17: ...the ANVIS dual visor assembly as follows a Align the locating pins with the slots in the mounting platform on the visor housing b Insert the pins into the slots and pull the mount down until it click...

Page 18: ...b Remove the thumbscrews from the visor assembly c Remove the visor housing from the tracks 2 Remove the four screws on the back of the ANVIS mount 3 Referring to Figure 2 13 place the ANVIS mount ag...

Page 19: ...oved the moleskin patch in Step 6 This will detach the power cord cover from the housing 8 Referring to Figure 2 16 align the power cord cover on the front of the housing and route the cord and connec...

Page 20: ...urls on the connector are seated between the ridges on the block 11 Referring to Figure 2 18 install moleskin patches supplied in the ANVIS mounting kit on the inside of the visor housing in the patte...

Page 21: ...mark the area with a pencil b Clean the marked area with isopropyl alcohol pads c Affix the pile fasteners within the marked area NOTE If the pile fastener pieces fail to stick to the helmet shell li...

Page 22: ...visor assembly away from the helmet posts 2 Referring to Figure 2 23 remove the visor housing as follows a Remove the four thumbscrews from the visor housing b Lift the visor housing away from the tr...

Page 23: ...the tracks c Release the knob to lock the visor in place 7 Referring to Figure 2 27 reinstall the retaining ring that you removed in Step 3 Ensure that the retaining ring is seated in the groove on th...

Page 24: ...ions cord connector at the rear of the helmet 2 Referring to Figure 2 30 remove the existing boom microphone as follows a Remove the center screw of the swivel assembly b Remove the interior screw tha...

Page 25: ...Tighten the screw to prevent the flex boom mount from moving on the helmet Re check the screw during periodic inspection to ensure tightness d Plug the microphone into the connector at the rear of the...

Page 26: ...the helmet Once you have disassembled these components you can connect the coiled cord and then reassemble and reinstall the components You will refer to Paragraph 3 3 7 Page 57 as follows 1 Remove th...

Page 27: ...ecified in Step 2 position the point of the compass in the dimple on one side of the helmet and draw an arc from approximately 2 inches to 2 1 2 inches below the dual visor assembly post as shown in F...

Page 28: ...erforming Steps 9 11 hold the drill perpendicular to the helmet shell to prevent damage to the shell and the energy absorbing liner Use the 2x4 block of wood as specified in Steps 9 11 to prevent dama...

Page 29: ...e of the visor to adjust the visor downstop to the lowest position 15 Referring to Figure 2 38 attach the MFS to the striker and latch the MFS into place as follows a On one side position the pin on t...

Page 30: ...g the two lower striker screws 17 Check the MFS position as follows a Raise the inner visor b Unlatch one side of the MFS and swing the MFS out ensuring that there is no interference with with dual vi...

Page 31: ...S latched in place and the two lower striker fasteners snug firmly hold a 2x4 block of wood inside the helmet shell behind the drilling point b Use a drill with a 1 16 inch drill bit to drill a pilot...

Page 32: ...en the screws 22 Clean the inside of the helmet to remove all debris resulting from drilling 23 Adjust the microphone boom as necessary so that it can be placed behind the MFS as shown in Figure 2 41...

Page 33: ...the flight suit The hair must be worn the same way thereafter Procedure 1 Before having the wearer don the helmet verify that the TPL or SCL seats down against and is aligned with the front edge of th...

Page 34: ...evaluate the fit As applicable do any of the following If a pressure point exists in the center of the forehead refer to Figure 2 44 and add headband fitting pads between the TPL or SCL and the energ...

Page 35: ...ger helmet size If the earseals are not sufficiently compressed have the wearer remove the helmet Add one or more earcup spacer pads Figure 2 46 as needed between the earcup retaining pad and the helm...

Page 36: ...pe strap is snug NOTE When the nape strap pad is centered both nape straps will be the same length b Check the fit of the pad by inserting two fingers index and middle between the pad and the wearer s...

Page 37: ...or lowered approximately one inch for visor to mask or facial conformance b When the desired position is attained tighten the screws 11 If night vision goggles are used place systems in normal operat...

Page 38: ...rating position as follows a Loosen the swivel by rotating it counterclockwise b Rotate the boom up or down c Slide the rear part of the boom forward or back d Tighten the boom swivel by rotating it c...

Page 39: ...rimming is needed If the goggles contact the shield trim the shield as specified in Paragraph 2 5 Page 35 d To remove the MFS flip the latch on one side of the MFS away from the helmet shell and remov...

Page 40: ...he free end from the chin pad and pushing the free end of the strap back through the toggle as needed b Grasp the helmet in the earcup areas and flex the helmet just enough to clear the head c Rotate...

Page 41: ...trim lines 5 Stow the goggles remove the shield NOTE Trim the MFS with the edge beading left in place You will cut through the edge beading and the shield Trim no more than necessary to allow the nig...

Page 42: ...Figure 2 55 set the oven rack to the lowest position heat the oven to 200 F 5 F 93 3 C 2 8 C CAUTION Before you place the TPL in the oven ensure that the cover is attached properly to the plastic laye...

Page 43: ...e nape strap pad Steps 8 13 should be completed in less than 30 seconds 8 Remove the TPL from the oven 9 Squeezing sides of TPL together to clear earcups install liner in helmet as shown in Figure 2 5...

Page 44: ...he wearer s peripheral vision Have the wearer maintain as much downward pressure as possible without causing discomfort for 3 5 minutes NOTE The TPL top should be compressed as much as possible this w...

Page 45: ...s possible before additional damage or failure occurs The preventive maintenance procedure consists of pre flight and post flight inspections The user should also keep the helmet clean The cleaning pr...

Page 46: ...e light colored inner fibers Inspect the edge for cracks Inspect the eardome area for holes or cracks TPL or SCL Check fit Inspect plastic layers for attachment Check for cover for dirt Energy absorbi...

Page 47: ...ircraft Check earphone for malfunctions using Test Set Intercommunications Unit Microphone Boom Assembly Check the attachment of hardware including set screws Check operation in aircraft Check microph...

Page 48: ...FS has holes cracks or any other damage Latches do not function properly Table 3 2 CLEANING COMPONENT CONDITION CLEANING Helmet shell Dirt grease scuff marks Use mild detergent and clean cloth Earcups...

Page 49: ...ubleshooting Procedures MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1 UNABLE TO RAISE OR LOWER VISOR LENS Step 1 Inspect for sediment or dirt buildup in tracks Clean tracks in accordance with Tab...

Page 50: ...ect boom swivel assembly for loose screw If unable to tighten screw replace in accordance with Paragraph 3 3 5 Page 55 wire boom or Paragraph 3 3 6 Page 56 flex boom 6 UNABLE TO ATTACH MFS Inspect MFS...

Page 51: ...is detected proceed to Step 4 If a failure is detected replace the communication cord in accordance with Paragraph 3 3 7 Page 57 Proceed to Step 5 NOTE Numbers in the Test 1 chart correspond to number...

Page 52: ...d unscrew the plug cover and check for any loose connections or cold solder joints Resolder any defective connections Proceed to step 5 NOTE Numbers in the Test 2 chart correspond to numbered call out...

Page 53: ...ex boom microphone Page 56 3 3 7 Communications cord Page 57 3 3 8 Dual visor assembly Page 60 3 3 9 MFS latches on shield Page 62 3 3 10 MFS strikers on helmet Page 63 47 When you replace components...

Page 54: ...lastic layers Replacement of thread is not necessary b Fold the sides of the cover down to expose the double sided tape c Remove the cover from the layers d Remove the double sided tape from the layer...

Page 55: ...by disengaging the hook and pile fasteners and pass the earcups through the retention straps Allow earcups to hang outside the helmet by communications cord 2 Referring to Figure 3 5 squeeze sides of...

Page 56: ...met Attach the pile fasteners on the energy absorbing liner to the hook fasteners on the inside of the helmet shell Ensure front edge of liner is aligned with front edge of helmet shell NOTE Installin...

Page 57: ...8 remove the TPL or SCL from the helmet 3 Referring to Figure 3 9 remove the pan head screw spring washer and post attaching the retention assembly to the center rear of the helmet shell Retain the s...

Page 58: ...f the helmet shell slide the liner into the helmet until the front edge of the liner is flush with the front edge of the helmet shell Ensure that the hook and pile fasteners are engaged NOTE Ensure th...

Page 59: ...earcup by stretching it carefully over the lip of the earcup shell b Remove the earphone holder from the earcup c Remove the earphone from the earphone holder d Using a jeweler s screwdriver loosen d...

Page 60: ...wo set screws 3 Insert the filler pad into the earcup ensuring that the slit in the pad is positioned toward the earcup hole Route the communications cord through the slit ensuring that the receiver a...

Page 61: ...e center screw attaching the microphone boom cord swivel assembly to the helmet Installation 1 Referring to Figure 3 15 attach the replacement microphone boom cord swivel assembly to the helmet Ensure...

Page 62: ...re 3 17 attach the replacement flex boom microphone to the helmet with the hardware Tighten the screw to prevent the flex boom mount from moving on the helmet 2 Referring to Figure 3 16 plug the micro...

Page 63: ...emove the earphones from the communications cord 3 Perform Steps 1 5 of Paragraph 3 3 2 beginning on Page 49 to remove the TPL or SCL and the energy absorbing liner from the helmet 4 Referring to Figu...

Page 64: ...from the outside of the helmet through the grommet hole so that only the connector and the grommet are on the outside of the helmet 2 Insert the grommet so that it is firmly seated in the hole 3 Refer...

Page 65: ...t with the screw washer and post 8 Perform Installation Steps 1 6 of Paragraph 3 3 2 Page 50 to reattach the nape strap pad and reinstall the TPL or SCL and the energy absorbing liner 9 Perform Instal...

Page 66: ...e the thumbscrews from the visor assembly 3 Remove the housing from the tracks 4 Disassemble the visors and the tracks by removing the retaining rings and the bushings Repeat for the other side NOTE A...

Page 67: ...pper track over the outer visor and install it in place on the bushings 5 Reinstall the retaining rings 6 Attach the housing to the tracks by inserting the thumbscrews through the housing and threadin...

Page 68: ...latch assembly by removing the screws and posts that attach the latch assembly to the MFS Installation Referring to Figure 3 25 attach the replacement latch assembly to the shield with the screws and...

Page 69: ...ferring to Figure 3 26 remove screws and posts attaching the striker to be replaced Installation Referring to Figure 3 26 install the new striker with the screws and posts 6 32 x 0 053 supplied in the...

Page 70: ...of each list correspond to numbered call outs in the figures For more information contact GENTEX Corporation Phone 570 282 3550 P O Box 315 Fax 570 282 8555 Carbondale PA 18407 www gentexcorp com 4 1...

Page 71: ...7 Post 8 32 x 3 16 For retention assembly 5 69A2104 3 8 Screw D 366 type 8 32 x 1 4 6 75A3093 9 9 Washer Spring 6 76A3443 10 Cord Assembly 25 CIP U174 plug 1 77C3523 1 11 Strain Relief Plate 1 69A2060...

Page 72: ...66 Figure 4 2 Dual Visor Assembly Plain 2 3 1 11 7 9 4 5 6 10 8...

Page 73: ...Lower Track Right Hand Not Shown 1 88D7615 2 5 Middle Track Left Hand 1 88C7616 1 Middle Track Right Hand Not Shown 1 88C7616 2 6 Upper Track Left Hand 1 88C7617 1 Upper Track Right Hand Not Shown 1...

Page 74: ...gure 4 3 DESCRIPTION QTY PART NO Earcup Assembly 98C10338 1 1 Shell Earcup Assembly 2 98C10337 1 2 Filler Pad 2 97B9974 1 3 Receiver Retainer 2 83C6573 4 Earseal 2 75C2990 68 Figure 4 3 Earcup Assembl...

Page 75: ...Preformed X Small 1 89D7779 2 Layer Assembly Preformed Small 1 89D7779 3 Layer Assembly Preformed Medium 1 89D7779 4 Layer Assembly Preformed Large 1 89D7779 5 Layer Assembly Preformed X Large 1 89D77...

Page 76: ...ONAL COMPONENTS Figures 4 5 through 4 9 show optional components For standard components see Figures 4 1 through 4 4 beginning on Page 64 70 Figure 4 5 Optional Components of HGU 56 P 1 2 3 4 5 6 7 8...

Page 77: ...11531 8 SCL X Small Breakdown Figure 4 8 1 02D11531 9 SCL Small Breakdown Figure 4 8 1 02D11531 10 SCL Medium Breakdown Figure 4 8 1 02D11531 11 SCL Large Breakdown Figure 4 8 1 02D11531 12 SCL X Larg...

Page 78: ...72 Figure 4 6 ANVIS Quick Disconnect Dual Visor Assembly 1 11 7 9 4 5 6 10 8 3 2 18 15 12 17 13 14 16...

Page 79: ...e Track Right Hand Not Shown 1 88C7616 2 6 Upper Track Left Hand 1 88C7617 1 Upper Track Right Hand Not Shown 1 88C7617 2 7 Adjustment Plate Left Hand 1 88B7622 1 Adjustment Plate Right Hand Not Shown...

Page 80: ...74 Figure 4 7 ANVIS Direct Mount Dual Visor Assembly 1 11 7 9 4 5 6 10 8 3 2 12 14 15 13...

Page 81: ...Shown 1 88C7616 2 6 Upper Track Left Hand 1 88C7617 1 Upper Track Right Hand Not Shown 1 88C7617 2 7 Adjustment Plate Left Hand 1 88B7622 1 Adjustment Plate Right Hand Not Shown 1 88B7622 2 8 Thumbscr...

Page 82: ...eformed X Small 1 02D11663 2 Layer Assembly Preformed Small 1 02D11663 3 Layer Assembly Preformed Medium 1 02D11663 4 Layer Assembly Preformed Large 1 02D11663 5 Layer Assembly Preformed X Large 1 02D...

Page 83: ...9 DESCRIPTION QTY PART NO Complete MFS includes MFS and all hardware 88C7626 1 MFS with Latches 1 96C9601 2 Hardware Kit Helmet Strikers 1 89C7816 1 3 Hardware Kit Shield Latches 1 89C7816 2 77 Figur...

Page 84: ...NOTES...

Page 85: ......

Page 86: ...PUBLICATION TP0113 REV 5 APRIL 2010...

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