Gentex HGU-84/P Operation And Maintenance Instructions
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Gentex HGU-84/P Operation And Maintenance Instructions

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OP ER A TION AND MAIN TE NANCE IN STRUC TIONS
WITH IL LUS TRATED PARTS LIST
HGU-84/P COM MER CIAL
HELMET AS SEM BLY
GENTEX COR PO RA TION
CAR BON DALE, PA
JUNE 2001
© 2001 GENTEX Cor po ra tion

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  • Page 1 OP ER A TION AND MAIN TE NANCE IN STRUC TIONS WITH IL LUS TRATED PARTS LIST HGU-84/P COM MER CIAL HELMET AS SEM BLY GENTEX COR PO RA TION CAR BON DALE, PA JUNE 2001 © 2001 GENTEX Cor po ra tion...

  • Page 2: Table Of Contents

    CON TENTS CHAP TER 1: IN TRO DUC TION AND GEN ERAL IN FOR MA TION 1-1 IN TRO DUC TION ........1-1 1-2 SCOPE .
  • Page 3 CON TENTS (Con tinued) 3-3 CLEANING ........3-3 3-4 SER VICING THE HELMET.

  • Page 4: In Tro Duc Tion

    1-1 IN TRO DUC TION The HGU-84/P Com mer cial Hel met As sem bly is de signed to pro vide eye, ear, and head pro tec tion when prop erly as sem bled and fit ted to the aircrew mem ber. It has a light - weight hel met shell con structed of graph ite, bal lis tic ny lon, fi ber glass, and ep oxy resin.

  • Page 5: 1-3.2 Helmet Shell As Sem Bly

    The TPL as sem bly co mes in three sizes: me dium, large, and ex tra large. CLOTH COVER Fig ure 1-3. TPL As sem bly TPL® is a reg is tered trade mark of GENTEX Cor po ra tion.

  • Page 6: 1-3.4 Earcup As Sem Blies

    1-3.4 EARCUP AS SEM BLIES (Fig ure 1-4) EARCUP The earcup as sem blies pro vide sound at ten u a tion and are com pat i ble with GROMMET EARSEAL H-87B/U and H-143 ear phones. These as sem blies are at tached via hook fas ten ers to the pile fas ten ers in stalled in side the hel met shell.

  • Page 7: 1-3.6 Eek-4 Sin Gle Vi Sor As Sem Bly

    LOCK MECHANISM 1-3.6 EEK-4 SIN GLE VI SOR AS SEM BLY (Fig ure 1-6) The EEK-4 is a sin gle-lens hel met vi sor as sem bly. When in stalled, the EEK-4 pro vides face and eye pro tec tion from im pact, pro jec tile pen e tra tion, sun glare, dust, windblast, and fire.

  • Page 8: Chap Ter 2: Prep A Ra Tion For Use

    CHAP TER 2 PREP A RA TION FOR USE 2-1 SIZING To se lect the proper size hel met shell as sem bly for the aircrew mem ber, pro ceed as fol lows: NOTE Ideally, aircrew mem bers will wear the same size hel mets as in pre vi ous des ig na tions.

  • Page 9: Helmet Fitting

    2-2. HELMET FITTING 1. Place the TPL in the hel met, en sur ing that the holes in the TPL plas tic lay ers are po si tioned to ward the front of the hel met. NOTE The TPL should seat down against, and align with, the front edge of the en ergy-ab sorb ing liner.
  • Page 10 5. Loosen the chin strap clamp screws, and slide the clamps (Fig ure 2-3) down as far as pos si ble on the chin strap. Ad just the nape straps for a snug fit. Slide the clamps to hold the ad justed straps in place, and tighten the screws.
  • Page 11 WARNING En sure that the chin strap is fas tened at all times when the hel met is worn. Fail ure to do so will re sult in a loss of hel met sta bil ity and may cause in jury or death.

  • Page 12: Fitting Of Tpl As Sem Bly

    2-3. FITTING OF TPL AS SEM BLY MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Fas tener tape, hook, pres sure sen si tive 85B7027 As re quired Tape, dou ble coated, vi nyl, ap prox i mately No.
  • Page 13 5. Have the aircrew mem ber don the hel met with the in stalled TPL by plac ing the front edgeroll on the fore head and ro tat ing the hel met as sem bly rear ward down onto the head.
  • Page 14 CAU TION Do not at tempt to heat the TPL in a toaster oven, as per ma nent dam age to the liner will re sult. Do not at tempt to heat the TPL in a mi cro wave oven, or dam age to the oven may re sult.
  • Page 15 NOTE Steps g and h are to be per formed by the aircrew mem ber as sisted by the main te nance tech ni cian, and should be ac com plished within 30 sec onds of re moval of the heated liner from the oven. g.

  • Page 16: Fitting Of Op Tional Bay O Net Re Ceiver As Sem Bly

    2-4. FITTING OF OP TIONAL BAY O NET RE CEIVER AS SEM BLY Ma te rials Re quired QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Bay o net Re ceiver As sem bly 93A8514 As re quired Ad he sive MIL-A-5540 NSN 8040-00-515-2245 CAU TION...
  • Page 17 5. While hold ing only the bay o net re ceiver spac ers against the hel met at the marked po si tions, use a lead pen cil as shown in Fig ure 2-9 to mark the screw holes onto the hel met shell.
  • Page 18 7. Hold the pile fas tener fab ric away from the hel met shell. Re ferring to Fig ure 2-11, in sert screws with lock wash ers through the backplate and the in side of the hel met shell. At tach the spac ers and re ceiv ers to the out side of the hel met shell. En sure that the jaw re ceiver pro jec tions point to the rear of the hel met.

  • Page 19: In Stal La Tion Of Light Weight Vi Sors

    2-5. IN STAL LA TION OF LIGHT WEIGHT VI SORS Ma te rials Re quired QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Light weight vi sor, clear 81D5189-3 Lightweight visor, neu tral gray 81D5189-4 Vi sor cover 82C5701 1.

  • Page 20: Anvis Mount Mod I Fi Ca Tion (Dual Vi Sor As Sem Bly)

    2-6. ANVIS MOUNT MOD I FI CA TION (DUAL VI SOR AS SEM BLY) Be fore the ANVIS NVG can be in stalled, the ANVIS mount must be mod i fied and a ca ble clip at tached. The ANVIS mod i fi ca tion kit con tains four screws for the rear of the mount, a ca ble clip and at tach ing screw, and pile fas tener for ANVIS bat tery pack at - tach ment to the hel met.
  • Page 21 6. Align the lo cat ing pins with the slots in the mount ing plat form on the hel met. In sert the pins into the slots and pull the mount down un til it clicks into place as shown in Fig ure 2-15.

  • Page 22: Chap Ter 3: Main Te Nance

    MAIN TE NANCE 3-1 GEN ERAL For op ti mum per for mance, the HGU-84/P hel met as sem bly must be used and main tained prop erly. Re pairs or other main te nance re quired shall be per formed upon is sue and at least ev ery 90 days there af ter.

  • Page 23: 3-2.3 Vi Sual In Spec Tion

    3-2.3 Vi sual In spec tion To vi su ally in spect the hel met as sem bly, pro ceed as fol lows : 1. In spect chin/nape strap as sem bly for loose or bro ken stitch ing, snap fas tener re ten tion, and fray ing.

  • Page 24: Cleaning

    3-3 CLEANING To clean the var i ous parts of this hel met as sem bly, pro ceed as fol lows: MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER As re quired De ter gent, laun dry Com mer cial As re quired Plas tic pol ish...

  • Page 25: Ser Vicing The Helmet

    4. Skull Cap. Laun dering of skull cap is re spon si bil ity of aircrew mem ber. CAU TION Han dle vi sors by edges only. Avoid scratch ing vi sors with rings, watches, buck les, and other metal or glass ob jects. Do not spray or splash cleaner di rectly onto vi sor or sub merge vi sor in any liq uid.

  • Page 26: 3-4.2 Re Place Ment Of Com Po Nents

    Ta ble 3-1. HGU-84/P As sem bly of Com po nents ORDER OF COM PO NENT / AS SEM BLY TO BE RE PLACED...

  • Page 27: 3-4.2.1 Re Place Ment Of Tpl Cover Or Layer As Sem Bly

    3-4.2.1 Re place ment of TPL Cover or Layer As sem bly MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Cover as sem bly, me dium 85D7088-1 Cover as sem bly, large 85D7088-2 Cover as sem bly, X-large 85D7088-3 Layer as sem bly, me dium 85D7518-1...

  • Page 28: 3-4.2.2 Re Place Ment Of Earcup As Sem Bly Or Ear Phone

    3-4.2.2 Re place ment of Earcup As sem bly or Ear phone MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Earcup as sem bly 90C7885 Ear phone 76A3242 To re place an earcup or ear phone, pro ceed as fol lows: EARCUP 1.
  • Page 29 6. Re place the earcup EARPHONE LEADS shell or ear phone as EARCUP ap pli ca ble. GROMMET 7. Re ferring to Fig ure 3-4, in stall the ear phone leads and grom met into the hole of the earcup. Se cure the grom met.

  • Page 30: 3-4.2.3 Re Place Ment Of Ear Phone Holder

    3-4.2.3 Re place ment of Ear phone Holder MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Ear phone Holder 79C4401-1 To re place an ear phone holder, pro ceed as fol lows: 1. Re move the earcup as sem bly from the pile fas tener on the in side of the hel met shell.

  • Page 31: 3-4.2.4 Re Place Ment Of Earseal

    3-4.2.4 Re place ment of Earseal MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Earseal 88C7589 To re place an earseal, pro ceed as fol lows: 1. Re move the earcup as sem bly from the pile fas tener on the in side of the hel met shell.

  • Page 32: 3-4.2.5 Re Place Ment Of Chin/Nape Strap As Sem Bly

    3-4.2.5 Re place ment of Chin/Nape Strap As sem bly MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Chin/Nape Strap As sem bly, Me dium, or 90C7864-1 Chin/Nape Strap As sem bly, Large, or 90C7864-2 Chin/Nape Strap As sem bly, X-Large, or 90C7864-3...
  • Page 33 2. Re place chin/nape strap as sem bly as fol lows: a. Lace the sin gle D-ring nape strap through the right-hand or left-hand (as worn) hel met slot de pend ing on aircrew mem ber pref er ence. NOTE The hook strip at the top of the nape pad should face the in side of the hel met shell.

  • Page 34: 3-4.2.6 Re Place Ment Of Chin Strap And Chin Pad

    3-4.2.6 Re place ment of Chin Strap and Chin Pad MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Chin strap as sem bly 90B7868 (Me dium, large, and X-large) or 90B7868-1 (X-large wide) Chin pad, black 91C8076-2 1.

  • Page 35: 3-4.2.7 Re Place Ment Of Nape Strap Clamp

    3-4.2.7 Re place ment of Nape Strap Clamp MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Clamp 93B8471 1. Re move the screws at tach - ing the clamp to the nape strap; re move the clamp. 2.
  • Page 36 SWIVEL ASSEMBLY SHAFT CONCAVE WASHER FLAT WASHER WASHER (INSIDE HELMET) SCREW Fig ure 3-15. Boom Swivel As sem bly 5. In stall the re place ment swivel as sem bly with the cupped side of the con cave washer against the out side of the hel met shell. 6.

  • Page 37: 3-4.2.9 Re Place Ment Of Op Tional Bay O Net Re Ceiver As Sem Bly

    3-4.2.9 Re place ment Of Op tional Bay o net Re ceiver As sem bly MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Bay o net Re ceiver As sem bly 93A8514 As re quired Ad he sive MIL-A-5540 1.
  • Page 38 2. Re place bay o net re ceiver as sem bly as fol lows: NOTE Each spacer should be fit ted against riv eted side of jaw re ceiver. A small amount of ad he sive may be ap plied to each screw prior to add ing lock washer and backplate.

  • Page 39: 3-4.2.10 Re Place Ment Of En Ergy-Ab Sorb Ing Liner

    3-4.2.10 Re place ment of En ergy-Ab sorb ing Liner. MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER 90D7860 En ergy-ab sorb ing liner (me dium) or 90D7861 En ergy-ab sorb ing liner (large) or En ergy-ab sorb ing liner 90D7862 (ex tra large) or...
  • Page 40 e. Gently pry in ward and up ward on the en ergy-ab sorb ing liner to ob tain suf fi cient clear ance to per mit grasp ing the liner with the free hand. f. Main tain up ward pres sure and con tinue to with draw the liner from the in te rior of the hel met shell.

  • Page 41: 3-4.2.11 Re Place Ment Of Dual Vi Sor As Sem Bly

    3-4.2.11 Re place ment of Dual Vi sor As sem bly MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Dual vi sor as sem bly Re move and re place the dual vi sor as sem bly as fol lows: NOTE The dual vi sor as sem bly is held to gether and at tached to the hel met with four screws;...
  • Page 42 OUTER VISOR LOCK ASSEMBLY VISOR HOUSING SCREWS (TWO EACH SIDE) SPACER OUTER VISOR TRACKS INNER VISOR NOTE: In the ex ploded view above, the vi sor lock is shown on the left side (as worn). The lock is nor mally in stalled on the right side as shown in this in set.

  • Page 43: 3-4.2.12 Re Place Ment Of Sin Gle Vi Sor As Sem Bly

    3-4.2.12 Re place ment of Sin gle Vi sor As sem bly MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Sin gle vi sor as sem bly, EEK-4, me dium 85B7024-1 Sin gle vi sor as sem bly, EEK-4, large 85B7024-2 Sin gle vi sor as sem bly, EEK-4, X-large 85B7024-3...
  • Page 44 4. Dis as sem ble the hous ing, tracks, and spac ers. NOTE Six posts (three on each side) ex ist in side the hel met shell. If these need to be re placed, re move the en ergy-ab sorb ing liner as de scribed in Para - graph 3-4.2.9 to ac cess them.

  • Page 45: 3-4.2.13 Re Place Ment Of Vi Sor Lock As Sem Bly

    3-4.2.13 Re place ment of Vi sor Lock As sem bly MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Vi sor lock as sem bly 75A3127 1. Ro tate the vi sor lock as sem bly a quar ter turn so that the vi sor key will clear the vi sor cut out and the hous ing slot;...

  • Page 46: 3-4.2.14 Re Place Ment Of Sin Gle Vi Sor Lens

    3-4.2.14 Re place ment of Sin gle Vi sor Lens MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Vi sor, Neu tral, Me dium 79D4405-1 Vi sor, Neu tral, Large 79D4406-1 Vi sor, Clear, Me dium 79D4405-2 Vi sor, Clear, Large 79D4406-2...

  • Page 47: 3-4.2.15 Re Place Ment Of Light Weight Vi Sor

    3-4.2.15 Re place ment of Light weight Vi sor MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Light weight Vi sor, Neu tral Light weight Vi sor, Clear CAU TION Avoid scratch ing the vi sor with ob jects such as rings, watches, buck - les, tools, or bench sur faces.

  • Page 48: 3-4.2.16 Re Place Ment Of Vi Sor Snap

    3-4.2.16 Re place ment of Vi sor Snap MA TE RIALS RE QUIRED QUAN TITY DE SCRIP TION REF ER ENCE NUMBER Snap Fas tener MS27983-3 1. Un snap the vi sor from the hel met in ac cor dance with Para graph 3-4.2.15, steps 1 and 2.

  • Page 49: Chap Ter 4: Il Lus Trated Parts Break Down

    4-1 GEN ERAL The Il lus trated Parts Break down (IPB) lists and il lus trates the pro cur able parts of the HGU-84/P Com mer cial Hel met. The IPB is in tended for use in the iden ti fi ca tion, pro cure ment, stor ing, and is su ing of re place ment parts.
  • Page 50 Fig ure 4-1. HGU-84/P Com mer cial Hel met As sem bly...
  • Page 51 • LIGHT WEIGHT VI SOR AS SEM BLY, MBU-12/P Trim, Neu tral Gray • VI SOR COVER, Gray Leather G, H, I, J Other con fig u ra tions avail able. Con tact Gentex Cor po ra tion for more in for ma tion.
  • Page 52 14, 15 Fig ure 4-2. Hel met Shell As sem bly Ta ble 4-2. Hel met Shell As sem bly FIG URE PART DE SCRIP TION UNITS US ABLE NUMBER IN DEX AS SEM BLY CODE NUMBER A, D HELMET SHELL ASSY, Me dium B, E HELMET SHELL ASSY, Large C, F...
  • Page 53 FIG URE PART DE SCRIP TION UNITS US ABLE NUMBER IN DEX AS SEM BLY CODE NUMBER • HELMET SHELL, Me dium, White A, D • HELMET SHELL, Large, White B, E • HELMET SHELL, X-Large, White C, F • HELMET SHELL, X-Large Wide, White •...
  • Page 54 Fig ure 4-3. TPL Ta ble 4-3. TPL FIG URE PART DE SCRIP TION UNITS US ABLE NUMBER IN DEX AS SEM BLY CODE NUMBER 85D7087-1P THER MO PLAS TIC LINER ASSY, Me dium A, D, G 85D7087-2P THER MO PLAS TIC LINER ASSY, Large B, E, H 85D7087-3P THER MO PLAS TIC LINER ASSY, X-Large C, F, I...
  • Page 55 Fig ure 4-4. Earcup As sem bly Ta ble 4-4. Earcup As sem bly FIG URE AND PART DE SCRIP TION UNITS PER US ABLE IN DEX NUMBER NUMBER AS SEM BLY CODE 90C7885 EARCUP AS SEM BLY • 90C7886-1 EARCUP, Left-hand (Not Shown) •...
  • Page 56 NAPESTRAP NAPESTRAP HELMET SHELL (REF) Fig ure 4-5. Chin/Nape Strap As sem bly...
  • Page 57 Ta ble 4-5. Chin/Nape Strap As sem bly FIG URE PART DE SCRIP TION UNITS US ABLE NUMBER IN DEX AS SEM BLY CODE NUMBER 90C7864-1 CHIN/NAPE STRAP ASSY, Me dium A, D, G 90C7864-2 CHIN/NAPE STRAP ASSY, Large B, E, H 90C7864-3 CHIN/NAPE STRAP ASSY, X-Large C, F, I...
  • Page 58 12 (SEE DETAIL) 13 (SEE DETAIL) DE TAIL Fig ure 4-6. Dual Vi sor As sem bly with Quick Disconnect 4-10...
  • Page 59 * Other col ors avail able; con tact Gentex Cor po ra tion for more in for ma tion. ** Other con fig u ra tions avail able; con tact Gentex Cor po ra tion for more in for ma tion.
  • Page 60 Fig ure 4-7. Sin gle Vi sor As sem bly 4-12...
  • Page 61 * Other col ors avail able; con tact Gentex Cor po ra tion for more in for ma tion. ** Other con fig u ra tions avail able; con tact Gentex Cor po ra tion for more in for ma tion.
  • Page 62 PUBLICATION TP0131 REV. 2 JUNE 2001...

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