TM-08744B-12&P

OPERATOR'S CARE AND USE MANUAL FOR

LIGHTWEIGHT HELMET (LWH)

8470-01-560-2866 - X-Small
8470-01-560-3267 - Small
8470-01-560-3076 - Medium
8470-01-560-3270 - Large
8470-01-560-3271 - X-Large
8470-01-560-3272 - XX-Large

PCN 500 087440 00

TM 08744B-12&P
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 procedures, please let us know. Mail your letter or DA Form
2028 (Recommended Changes to Publications and Blank Forms) direct to:
Commanding General, MARCORSYSCOM, Attn: CESS - PM ICE, 2200 Lester
Street, Quantico, VA 22134-6050. A reply will be furnished to you.

DESTRUCTION NOTICE: For unclassified, limited, destroy by any method that

will prevent disclosure of contents or reconstruction of the documents.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government

Agencies and their contractors. This publication is provided for official use or
operational purposes only. Other requests for this document shall be referred
to: Commandant of the Marine Corps (AREB), Washington, D.C. 20380-0001.

TM 08744B-12&P

WARNING
If your helmet is equipped with a mesh crown suspension system, this system must
be removed from the helmet and replaced with a pad suspension system per
MARADMIN 480/06, dated October 5, 2006.
When retrofitting to pads, discard the screws and A-nuts; do not reuse them.
The hardware (nut) inside the helmetwhere the retention system webbing attaches
to the helmet (in four places)must be covered by padding at all times. Failure to
observe this precaution could result in serious injury or death.
If you experience fit problems, tightness, looseness, or the helmet is too high or too
low, refer to Paragraph 3.4.2, Troubleshooting the Fit.
The helmet provides the most impact protection using the standard seven-pad
configuration. This pad configuration provides the required impact protection at all
required impact sites.
Alternate pad configurations may not provide optimal protection at all required impact
sites.
Never remove the crown pad.
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 may result in injury.
i

WARNING
Always wear the helmet with the chinstrap properly fastened and adjusted. Failure to
secure the chinstrap will decrease helmet stability and may result in injury to the
wearer.
Replace the helmet if dents or cuts measuring over 2 inches exist or are deeper than
1/8 inch, or if any delaminations (ply separations) exist. Failure to do so may result in
reduced head protection.
Replace the helmet if edge beading is missing or loose. Missing or loose edge
beading will result in exposed rough helmet edges that may cause injury.
Replace the retention assembly if the webbing is torn or frayed, if the nape strap
buckles are broken, or if the buckle pad buckle is damaged. Replace missing
hardware and tighten loose hardware. Failure to do so may result in injury.
Replace any chinstrap that is cut or torn, has broken buckles, or has hook/pile
fasteners that do not secure. Failure to do so may result in injury.
Replace missing or damaged pads. Failure to do so will result in a helmet that may
not protect the wearer. Replace pads after 6 months of regular use.
Use only the screws and A-nuts described in this manual.
For the wearer's safety, ensure that the screws do not protrude through the A-nuts
when installed.
ii

TM 08744B-12&P

Contents
1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Suspension and Retention System . . . . . . . . . . . . . . . . . . . . . 2

HELMET RETROFIT NOTICE . . . . . . . . . . . . . . . . . . . . . . . . 3

3. HELMET PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Selecting Helmet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Switching Chinstrap Buckle to Other Side (Optional). . . . . . . . . . . 10
3.3 Installing Helmet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Checking Helmet Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Final Fit Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.6 Donning/Doffing/Operation . . . . . . . . . . . . . . . . . . . . . . . . . 35

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4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Preventive Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Removal and Installation of Components . . . . . . . . . . . . . . . . . 42
4.5 Retrofitting the Helmet (Removing Headband/Crown Pad Suspension
and Installing Pad Suspension) . . . . . . . . . . . . . . . . . . . . . . 47

5. NATIONAL STOCK NUMBERS (NSN) LIST . . . . . . . . . . . . . . . . 53

6. CONSUMABLE ITEMS LIST . . . . . . . . . . . . . . . . . . . . . . . . 55

iv

TM 08744B-12&P
NOTE: The National Stock Numbers (NSNs) for the major components of this
item are listed in Section 5.

1. GENERAL INFORMATION
1.1

Type of Manual. Operator care

and use manual.

1.2

Helmet Name. Lightweight

Helmet (LWH), shown in
Figure 1.

1.3

Purpose of Helmet. Provide

ballistic, fragmentation,
hand-gun, and impact protection.

Figure 1. Lightweight Helmet

2. COMPONENT DESCRIPTION
The helmet consists of a helmet shell incorporating state-of-the-art composite
materials to enhance protection with reduced weight, and an improved suspension
and retention system for comfort and stability. It is available in five sizes, allowing for
optimum fit and stability.
1

TM 08744B-12&P
2.1 Suspension and Retention System
The suspension and retention system (Figure 2) consists of the following components:

Pad Suspension System. The pad

suspension system is a set of seven pads
providing sizing and fitting adjustments.
CHINSTRAP
In conjunction with the shell, the pad
suspension system provides impact
protection. In conjunction with the chin/nape
retention system, the pad suspension system
provides stability. The helmet has
3/4-inch-thick pads installed; they can be
replaced with 1-inch-thick pads if necessary
(except for the crown pad at the center top of
the helmet; it is always 3/4-inch).

Chin/Nape Retention System. The

integrated chin/nape retention provides
stability and comfort. It includes a nape pad
with adjustable straps and an adjustable
chinstrap. The chinstrap (also available
separately) can be configured to fasten
and unfasten on the right or left side.
2

RETENTION
ASSEMBLY
NAPE
PAD

PAD
SUSPENSION
SYSTEM

RETENTION
ASSEMBLY

Figure 2. Pad Suspension and

Chin/Nape Retention Systems

TM 08744B-12&P

HELMET RETROFIT NOTICE

WARNING

CROWN PAD
SUSPENSION

If your helmet is equipped with a

headband/crown suspension system
(shown at right), this system must be
removed from the helmet and replaced with
a pad suspension system per MARADMIN
480/06, dated October 5, 2006. Failure to do
so will result in reduced impact protection,
which can increase the risk of injury.
NOTE
In this retrofit, the center front and center
rear holes of the helmet are to be plugged
with hardware supplied for this task.

HEADBAND

Headband/Crown Pad
Suspension System

Perform the retrofit procedure in Paragraph 4.5. Then return to Paragraph 3, Helmet
Preparation, and perform all fitting and adjustment procedures.
3

TM 08744B-12&P
3. HELMET PREPARATION
Helmet preparation consists of (1) selecting the helmet size, (2) switching the
chinstrap buckle to the other side of the helmet (optional), and (3) checking the
helmet fit making adjustments as necessary.

3.1 Selecting Helmet Size

Helmet sizes are X-Small, Small, Medium, Large, X-Large, and XX-Large.
To determine proper helmet size, you must (1) measure and record the wearers
head length, (2) measure and record the wearers head width, (3) measure and
record the wearers head circumference, and (4) select the helmet size based
upon established parameters and guidelines.
3.1.1 Tools/Equipment Needed

Caliper

Ruler

Tape measure

TM 08744B-12&P
3.1.2 Measuring Head Length
(1) Use a caliper and a ruler
as shown in Figure 3 to
measure the distance (to
the nearest 1/16 inch)
from the glabella
landmark (point between
the eyebrows) to the
back of the head. This is
the head length. Ensure
that the caliper touches
the skin lightly and does
not indent the skin
surface.
(2) Record the
measurement.

Glabella
landmark
Measurement
point

USE OF CALIPER

Figure 3. Measuring Head Length

TM 08744B-12&P
3.1.3 Measuring Head Width
(1) Use a caliper and a ruler as
shown in Figure 4 to
measure the maximum
horizontal width (to the
nearest 1/16 inch) of the
head above the ears. This
is the head width. Ensure
that the caliper touches the
skin lightly and does not
indent the skin surface.

Maximum horizontal width

POINTS TO
MEASURE

(2) Record the measurement.

USE OF CALIPER

Figure 4. Measuring Head Width

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TM 08744B-12&P
3.1.4 Measuring Head Circumference
(1) Use a tape measure
as shown in Figure
5 to measure the
maximum head
circumference (to
the nearest 1/16
inch) of the head
above the ears.
(2) Record the
measurement.
TAPE MEASURE

Figure 5. Measuring Head Circumference

TM 08744B-12&P
3.1.5 Using Sizing Parameters to Select Helmet Size
(1) Compare the head length, head width, and head circumference measurements
to the sizing parameters shown in Table 1.
Table 1. Sizing Parameters

*
8

MEASUREMENTS - inches up to maximum*

HELMET
SIZE

Head Length

Head Width

Head Circumference

X-Small

7-1/8

5-5/8

20-7/8

Small

7-1/2

5-7/8

21-3/4

Medium

7-3/4

6-1/8

22-1/2

Large

8-1/8

6-1/4

23-1/4

X-Large

8-5/8

6-7/8

24-1/4

XX-Large

Larger than 8-5/8

Larger than 6-7/8

Larger than 24-1/4

Be sure to take all three measurements.

TM 08744B-12&P
(2) Of the three measurements (head length, head width, and head
circumference), select the measurement that corresponds to the largest
helmet size. For example, if the head length corresponds to helmet size
Large, and the other two measurements correspond to helmet size Medium,
select helmet size Large.

NOTE
The use of both a balaclava and an M-40 mask adds inch to the users head
width and 5/16 inch to the users head length. This may place the wearer into the
next larger helmet size when the balaclava and the M-40 mask are worn. If this
is the case, it is recommended that the larger helmet size be selected.

TM 08744B-12&P
3.2 Switching Chinstrap Buckle to Other Side (Optional)
The chinstrap buckle is factory-installed on the left side (as worn) of the helmet.
However, if necessary, the chinstrap buckle can be switched to the right side (as
worn) to accommodate left-handed shooters. Following is the procedure for moving
the chinstrap buckle to the right side.
NOTE
When properly installed, the
pile fastener on the chinstrap
will be on the bottom, under the
chin, and the attached loop will
be on the top of the chinstrap.
(1) Referring to Figure 6,
unbuckle the chinstrap.
Detach the ends of the
chinstrap from the pile
fastener, and unlace the
chinstrap from both the
buckle and the slide
adjustment.
10

PILE
FASTENER
CHINSTRAP
LOOP

BUCKLE

ENDS OF
CHINSTRAP

SLIDE
ADJUSTMENT

Figure 6. Chinstrap

TM 08744B-12&P
(2) Reverse the
chinstrap so that
the end that was
laced through the
buckle is now
aligned with the
slide adjustment.
Lace this end
through the slide
adjustment; lace
the other end
through the buckle.
Reattach the ends
of the chinstrap to
the pile fastener.
The chinstrap loop
will now appear
upside down as
shown in Figure 7.

SLIDE
ADJUSTMENT
(SHOWN FROM
OTHER SIDE)

CHINSTRAP
PILE
FASTENER
ENDS OF
CHINSTRAP

BUCKLE

Figure 7. Chinstrap Reversed

11

TM 08744B-12&P
(3) Refer to Figure 8. If
your retention has
two attachment holes
in each strap, note
which hole on the
front retention straps
is used. On one side
of the helmet, remove
the front screw that
attaches the front
retention strap to the
helmet. (The conic
nut will also be
removed from the
inside of the helmet.)
Note how the conic
nut is positioned in
the front strap inside
the helmet; you will
reinstall the conic nut
in the same manner
later.
12

CONIC
NUT

FRONT
STRAP

HARDWARE
ATTACHMENT
FRONT
SCREWS

SCREW

FRONT
RETENTION
STRAP

FRONT
RETENTION
STRAP

Figure 8. Hardware Locations and Front Straps

TM 08744B-12&P
(4) Referring to
Figure 9, unlace
the front strap
from the pad.
Then unlace the
rear strap from
the pad.
(5) Repeat Steps 3
and 4 on the other
side of the helmet
to unlace the front
and rear retention
straps from the
pad.

FRONT
RETENTION
STRAP

FRONT
RETENTION STRAP

REAR
RETENTION
STRAP
SLIDE
ADJUSTMENT
PAD
PILE FASTENER

REAR
RETENTION
STRAP
BUCKLE
PAD

Figure 9. Straps and Pads

13

TM 08744B-12&P
(6) Refer to Figure 10. Take the buckle
pad that was on the left side (as
worn) and orient it on the right side
of the helmet. Ensure that the
buckle side of the buckle pad faces
outward. Lace the right rear
retention strap through Slot A in the
buckle pad and elastic loop. Then
lace the right front retention strap
through Slot B in the buckle pad.
(7) Refer to Figure 11. Take the slide
adjustment pad that was on the right
side (as worn) and orient it on the
left side of the helmet. Ensure that
the slide adjustment side faces
outward. Lace the left rear retention
strap through Slot A in the slide
adjustment pad and the elastic loop.
Then lace the left front retention
strap through Slot B in the slide
adjustment pad.
14

RIGHT FRONT
RETENTION
STRAP

RIGHT REAR
RETENTION STRAP

SLOT B
ELASTIC
SLOT A
LOOP

Figure 10. Buckle Pad

LEFT FRONT
RETENTION
STRAP

LEFT REAR
RETENTION STRAP

SLOT B
SLOT A ELASTIC
LOOP

Figure 11. Slide Adjustment Pad

TM 08744B-12&P
(8) Refer to Figure 12.
Attach the right
front retention
strap to the helmet
using the
hardware removed
previously. Be
sure to position
the slot in the
conic nut toward
the inside of the
helmet.
(9) Repeat Step 8 on
the other side of
the helmet to
complete the
procedure.
Ensure that the
chinstrap pile
fastener is at the
bottom.

FRONT
STRAP

CONIC
NUT

SCREW
FRONT SCREWS

LEFT
FRONT
STRAP

RIGHT
FRONT
STRAP

PILE
FASTENER

Figure 12. Chinstrap Buckle on Other Side

15

TM 08744B-12&P
3.3 Installing Helmet Cover

FRONT

If you wear a helmet cover (Item 12, NSN List),

refer to Figure 13 and install the cover as
follows:

TAB
HOOK
DISK

(1) Remove the suspension pads from the

inside of the helmet, noting their
positioning and arrangement.
(2) If the helmet cover is reversible, orient it
so that the desired color or pattern is on
the outside.
(3) Align the end of the cover with two
buttonholes at the back of the helmet
and the end without buttonholes at the
front of the helmet.
(4) Pull the cover over the helmet.
(5) Attach the tabs on the cover to the hook
disks on the helmet.
(6) Reinstall the suspension pads in the
same position and arrangement as
before.
16

BACK

BUTTONHOLES

Figure 13. Helmet with

Suspension Pads Removed
and Cover Installed

TM 08744B-12&P
3.4 Checking Helmet Fit
To check the helmet fit, you must (1) don the helmet and adjust the retention and the
chinstrap, (2) evaluate the fit, (3) troubleshoot the fit (if necessary) to eliminate any
problems, and (4) become familiar with alternate pad configurations.
3.4.1 Donning Helmet and Evaluating Fit

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 and may result
in injury.
Do the following:
(1) Ensure that the suspension pads are
arranged in the standard pad configuration
(see Figure 14). If other equipment is to
be used with the helmet, such as a
headset, evaluate size with that
equipment (if possible).

Figure 14. Standard Pad

Configuration
17

TM 08744B-12&P
(2) Referring to Figure 15,
do the following:
(a) Don the helmet.
(b) Ensure that the
buckle pads are
below the earlobes.
If the buckle pads
cover the earlobes,
lower the front
retention strap
buckles until the
buckle pads are
below the earlobes.
(c) Buckle the chinstrap.
(d) Adjust the nape
straps for a snug,
secure, comfortable
fit at the nape.

FRONT RETENTION STRAP

ADJUSTMENT BUCKLE
(ONE ON EACH SIDE)

BUCKLE
PADS

ENDS OF
CHINSTRAP

NAPE STRAP
ADJUSTMENT
(ONE ON
EACH SIDE)

CHINSTRAP
BUCKLE

Figure 15. Nape Strap, Front Retention

Strap, and Chinstrap Adjustment
18

TM 08744B-12&P
(e) Tighten the chinstrap by pulling on the hook ends of the chinstrap until the
fit is snug, secure, and comfortable. Reattach the ends to the pile
fastener when the desired fit is attained.
(f)

Check the helmet stability by attempting to rock the helmet back and forth
on the head. If the helmet rocks back and forth, it is not stable. Adjust
the nape strap further until the helmet is stable.

(g) If the buckle pads cover the earlobes when the nape strap is adjusted,
lower the front retention strap buckles until the buckle pads are below the
earlobes. Repeat Steps 2d through 2g as necessary. Recheck helmet
stability; no straps should be loose.
(3) Evaluate the fit of the helmet. The helmet should not be too high (crown pad
does not contact the head or too much of forehead is exposed), too low (too
low on brow or not compatible with eyewear, etc.), too tight, or too loose.
Shake head rapidly from side to side to check for stability. The helmet should
not rotate from side to side when head is shaken. If any of these problems
exist, follow Paragraph 3.4.2.

19

TM 08744B-12&P
3.4.2 Troubleshooting the Fit
This section provides sizing and
fitting troubleshooting techniques.
(1) If the helmet is too tight:
(Figure 16):

Try arranging the oblong

(smallest) pads in a
horizontal configuration or
diagonal direction (see pad
configuration illustrations in
Paragraphs 3.4.3.1 and
3.4.3.2).

If rearranging the pads does

not alleviate the tightness,
try the next larger helmet
size.
Figure 16. Helmet Too Tight

20

TM 08744B-12&P
(2) If the helmet is too loose,
that is, if it slides when you
shake your head from side to
side (Figure 17):

If available, try a thicker

pad set. Remove the
3/4-inch-thick pads from
the helmet (except the
crown pad); replace them
with the 1-inch-thick pads.
Note: Only 3/4-inch-thick
crown pads are available.

Select the next smaller

helmet size.
Figure 17. Helmet Too Loose

21

TM 08744B-12&P
(3) If the helmet is too high, that is, if too much forehead is exposed (Figure 18), if
the crown pad does not touch the top of the head (Figure 19), or if the wearer
does not see the edge of the rim (Figure 20):

Try rearranging pads (horizontal or diagonalsee pad configuration

illustrations in Paragraphs 3.4.3.1 and 3.4.3.2).

Try a larger helmet size.

It is extremely important that
the helmet not sit too high
on the head. Here are some
things to look for:
a.

MORE THAN
-INCH
ABOVE
EYEBROW

Refer to Figure 18.

If too much of the
forehead is exposed
(approximately more
than -inch above
eyebrow), then the
helmet is too high.
Figure 18. Too Much Forehead Exposed

22

TM 08744B-12&P
b.

Refer to Figure 19.

If the crown pad does
not touch the head (if
you cannot feel the
pad), then the helmet is
too high.

SPACE BETWEEN PAD AND HEAD

Figure 19. Crown Pad Not Touching Head

23

TM 08744B-12&P
c.

Refer to Figure 20.

Look upward by
moving your eyes, but
without moving your
head. If you cannot see
the brim of the helmet,
then the helmet is too
high.
WEARER
CANNOT
SEE BRIM

Figure 20. Looking Past Brim

24

TM 08744B-12&P
(4) If the helmet is too low on the brow, not compatible with eyewear, or has other
compatibility issues (Figure 21):

Try rearranging pads

(horizontal or
diagonalsee pad
configuration illustrations
in Paragraphs 3.4.3.1
and 3.4.3.2).

Try a smaller helmet.

If available, try a thicker
pad set. Remove the
3/4-inch-thick pads
(except the crown pad)
from the helmet; replace
them with the 1-inch-thick
pads.
Note: Only 3/4-inch-thick
crown pads are available.

BRIM
INTERFERES
WITH VISION
AND EYEWEAR

Figure 21. Helmet Too Low

25

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3.4.3. Pad Suspension Adjustment and Configurations
This section provides information about the adjusting and configuring of the pad
suspension system. This unique suspension system is fully adjustable. The system
has the following requirements and restrictions:

WARNING
The hardware (nut) inside the helmetwhere the retention system webbing
attaches to the helmet (in four places)must be covered by padding. The
oblong/oval pad must be placed flush with the rim (edge) of the helmet and
completely cover the hardware; see Figure 22 (next page). Failure to observe
this precaution could result in serious injury or death.
For maximum stability, place pads as close as possible to the edge of the helmet.
If you experience fit problems, tightness, looseness, or the helmet is too high or
too low, refer to Paragraph 3.4.2, Troubleshooting the Fit.

26

TM 08744B-12&P

OBLONG/OVAL PAD

HARDWARE (NUT)
UNDER PAD
OBLONG/OVAL
PAD
HARDWARE (NUT)
UNDER PAD

OBLONG/OVAL PAD

HARDWARE (NUT)
UNDER PAD
OBLONG/OVAL
PAD

HARDWARE (NUT)
UNDER PAD

Figure 22. Pad Placement Over Hardware (Four Places)

27

TM 08744B-12&P
NOTE
When donning the helmet for the first time in a cold environment, it is necessary
to wear the helmet for a few minutes or otherwise warm the pads, such as by
placing in pockets, so that the pads will conform to the shape of your head. As
the pads warm up and conform to the shape of your head, it may be necessary to
re-tighten the chinstrap and the retention system.
NOTE
If you experience hot spots or discomfort, try rearranging the pad system to
accommodate a more comfortable fit. (See Paragraphs 3.4.3.1 and 3.4.3.2.) If
discomfort persists, try another helmet size. (See Paragraph 3.1.)

28

TM 08744B-12&P
3.4.3.1 Standard Seven-Pad Configuration

WARNING
All seven pads provide maximum impact protection. Never remove the crown
pad. Failure to observe this precaution could result in serious injury or death.
Figure 23 shows the standard seven-pad configuration, with the pads placed
vertically. The pads may also be placed in other directions as described on the next
page.
NOTE: Size XX-Large contains the standard seven-pad configuration plus two
additional oblong/oval pads, one positioned above each eardome.
FRONT

TRAPEZOIDAL PAD
OBLONG/OVAL PAD

OBLONG/OVAL PAD

CROWN PAD
OBLONG/OVAL PAD

OBLONG/OVAL PAD
TRAPEZOIDAL PAD

Figure 23. Standard Pad Configuration

29

TM 08744B-12&P
Pads can be placed in vertical or horizontal directions (as shown in Figure 24) or a
combination or at an angle between horizontal and vertical (diagonal).
The vertical configuration maximizes airflow for better temperature regulation. The
horizontal configuration makes a seal around the users head and is better suited for
cold weather environments.
Hardware MUST be covered with pads at all times.
FRONT
PADS PLACED
VERTICALLY

FRONT
PADS PLACED
HORIZONTALLY

Figure 24. Vertical and Horizontal Pad Placement

30

TM 08744B-12&P
3.4.3.2. Alternate Non-Standard Pad Configurations

WARNING
The helmet provides the most impact protection using the standard seven-pad
configuration.
Alternate pad configurations may not provide optimal protection.
Never remove the crown pad.
Alternate pad configurations (shown on the next two pages) are allowed to obtain a
better fit or more comfort.
Pads can be placed in vertical or horizontal directions (as shown in illustrations) or
a combination or at an angle between horizontal and vertical (diagonal).

Up to two pads (trapezoid or oblong/oval) can be removed in non-risk situations.

The circular crown pad must always remain in the helmet.

An oblong/oval pad can be substituted for a trapezoidal pad.

Pads should be placed around the inside of the helmet to provide optimum
comfort and stability.

Hardware should be covered with pads at all times.

For size X-Large, up to nine pads may be used.
31

TM 08744B-12&P
Figures 25 and 26 show non-standard pad configurations. For reasons of clarity only,
each of the illustrations shows pads in either horizontal or vertical positions but not in
diagonal positions. However, the pads can be placed diagonally, at any angle.
Figure 25 shows the five-pad configuration.

PADS PLACED
VERTICALLY

FRONT

FRONT

Figure 25. Five-Pad Configuration

32

PADS PLACED
HORIZONTALLY

TM 08744B-12&P
The six-pad configuration (Figure 26) is useful for wearers who have long heads or
when protective masks are worn. Optionally, you may substitute a fifth oblong/oval
pad for the trapezoidal pad.
PADS PLACED
VERTICALLY

FRONT

FRONT

PADS PLACED
HORIZONTALLY

OBLONG/OVAL
PAD

TRAPEZOIDAL
PAD
Figure 26. Six-Pad Configuration

33

TM 08744B-12&P
3.5 Final Fit Check
Do the following:
(1) Don the helmet as shown in
Figure 27 and check the fit in
accordance with paragraph 3.4.1.
(2) Check the helmet stability by
attempting to rock the helmet
back and forth on the head. If the
helmet rocks back and forth, it is
not stable. Adjust the nape straps
in accordance with paragraph
3.4.1 until the helmet is stable.
(3) Make any necessary adjustments
in accordance with paragraph
3.4.1.

ENDS OF
CHINSTRAP
ATTACHED
TO PILE
FASTENER

CHINSTRAP
FASTENED

Figure 27. Helmet Donned

34

TM 08744B-12&P
3.6 Donning/Doffing/Operation

WARNING
Always wear the helmet with the chinstrap
properly fastened and adjusted. Failure to
secure the chinstrap will decrease helmet
stability and may result in injury to the
wearer.

HELMET
FRONT
BRIM

(1) Don the helmet, ensuring that the

helmet front brim rests just above the
eyebrows.
(2) Refer to Figure 28. Buckle the
chinstrap. Ensure that it fits securely
on the chin.
BUCKLE

Figure 28. Chinstrap Buckle

35

TM 08744B-12&P
(3) Refer to Figure 29. Check the fit
in accordance with paragraph
3.4.1. Adjust the chinstrap, if
required, as follows:
(a) Detach the ends of the
chinstrap from the pile
fastener.
(b) Pull on the ends until the
chinstrap fits snugly,
securely, and comfortably.
(c) Reattach the ends of the
chinstrap securely to the
pile fastener.
(4) To doff the helmet, unbuckle the
chinstrap and remove the helmet
from the head.

36

PILE
FASTENER

END OF CHINSTRAP
(BOTH SIDES)

Figure 29. Chinstrap

TM 08744B-12&P
4. MAINTENANCE
4.1 Preventive Maintenance Checks
Table 2 lists the preventive maintenance tasks for each component and refers you to
the appropriate procedure.
Tools Needed: Two " flat-blade screwdrivers (Special Tools: None)
Table 2. Preventive Maintenance Checks
COMPONENT

EXAMINE FOR:

HELMET IS NOT
READY IF:

Helmet
Shell
(Item 11,
NSN List

Dents or cuts greater than 2 inches or deeper than

1/8 inch, or any delaminations.

Helmet shell has

dents or cuts
greater than 2
inches or deeper
than 1/8 inch exist,
or any
delaminations exist.

Edge
Beading

Missing or loose edge beading.

WARNING
Replace the helmet if dents or cuts measuring over
2 inches exist or are deeper than 1/8 inch, or if any
delaminations exist. Failure to do so may result in
reduced head protection.

WARNING

WHERE
FOUND

Edge beading is
missing or loose.

Replace the helmet if the edge beading is missing or

loose. Missing or loose edge beading will result in
exposed rough helmet edges that may cause injury.

37

TM 08744B-12&P
Table 2. Preventive Maintenance Checks
COMPONENT

EXAMINE FOR:

Retention
Assembly
(Item 5,
NSN List)

Torn/frayed webbing, broken nape strap buckles,

damaged buckle pad, or missing or loose attaching
hardware.

Chinstrap
(Item 6,
NSN List)

Broken buckles; torn, cut, or frayed webbing; or

worn hook/pile fasteners.

38

HELMET IS NOT
READY IF:

WHERE
FOUND

Webbing is torn or Paragraph

frayed, nape strap 4.4.2
buckles are
WARNING
broken, buckle pad
Replace the retention assembly if the webbing is
buckle is broken,
torn or frayed, if the nape strap buckles are broken, or attaching
or if the buckle pad buckle is damaged. Replace
hardware is loose
missing and tighten loose hardware. Failure to do so or missing.
may result in injury.
Buckles are
Paragraph
broken; webbing is 4.4.1
cut, torn or frayed;
WARNING
or hook/pile
Replace any chinstrap that is cut or torn, has broken fasteners do not
buckles, or has hook/pile fasteners that do not
secure.
secure. Failure to do so may result in injury.

TM 08744B-12&P
Table 2. Preventive Maintenance Checks
COMPONENT

EXAMINE FOR:

HELMET IS NOT
READY IF:

WHERE
FOUND

Pads
(Item 2
or 3,
NSN List)

Cuts, tears or other damage to outer fabric or inner

foam; pads not adhering to hook disks. Replace the
pads if they are torn or cut, exposing the inner
padding.

Pads are torn, cut

or otherwise
damaged; or pads
will not adhere to
hook disks.

Paragraph
4.4.3

WARNING
Replace missing or damaged pads. Failure to do so
will result in a helmet that may not protect the
wearer.

NOTE
Pads should be replaced after 6 months of
continuous daily use.
Hook
Loose or damaged hook disks. Replace the hook
disks
disks as necessary.
(Item 4,
NSN List)

Hook disks are

Paragraph
damaged such that 4.4.4
they will not
securely hold the
pads in place

39

TM 08744B-12&P
4.2 Cleaning
Table 3 lists the cleaning procedure for each of the helmet components.
Table 3. Cleaning
COMPONENT

PROCEDURE

Helmet Shell
(Item 11, NSN List)

Wipe clean with damp cloth.

Pad Suspension
(Item 2 or 3, NSN List)

Hand-wash with mild soap and water. Rinse well and

air-dry. (Do not machine-wash or machine-dry.)

Leather Components

Clean with soap, rinse thoroughly, wipe dry with clean

cloth.

Retention Assembly
(Item 5, NSN List)

Wipe clean with damp cloth.

40

TM 08744B-12&P
4.3 Troubleshooting
Listed below are the troubleshooting tasks for each component, along with the
appropriate repair procedure.
(1) Malfunction:
Test/Inspection:

Unable to fasten or adjust chinstrap (Item 6, NSN List)

Inspect chinstrap for defective webbing, buckles, or
hook/pile fasteners.
Corrective Action: Replace chinstrap as in Paragraph 4.4.1.

(2) Malfunction:
Test/Inspection:

Unable to attain/maintain helmet stability

Inspect retention assembly (Item 5, NSN List) for
defective buckles or torn/frayed webbing.
Corrective Action: Replace retention as in Paragraph 4.4.2.
Test/Inspection:

Inspect pads (Item 2 or 3, NSN List) for damage, wear,

or loss of adhesion
Corrective Action: Replace pads as in Paragraph 4.4.3.

41

TM 08744B-12&P
4.4 Removal and Installation of Components
4.4.1 Chinstrap
NOTE: This procedure is for helmets with the chinstrap
buckle installed on the left side (as worn). If your chinstrap
buckle has been switched to the right side, perform this
procedure accordingly (fasten/unfasten buckle on right,
lace/unlace chinstrap on left).
a. Removal
(1) Refer to Figure 30. Unfasten the chinstrap buckle
on the left side (as worn) of the retention assembly.
(2) Unlace the chinstrap (Item 6, NSN List) from the
right side (as worn) of the retention assembly.
b. Installation
(1) Lace the chinstrap through the buckle on the right
side (as worn) of the retention assembly.
(2) Don the helmet. Fasten the chinstrap to the buckle
on the left side (as worn) of the retention assembly.
(3) Check the fit in accordance with Paragraph 3.4, and
make any necessary adjustments.
42

LACE/
UNLACE

FASTEN/
UNFASTEN

Figure 30. Chinstrap

TM 08744B-12&P
4.4.2 Retention Assembly
a.

Removal
(1) Inside the helmet,
remove the pads that
cover the four
retention hardware
locations shown in
Figure 31.
(2) Remove the screws
shown in Figure 31
(Item 9, NSN list) and
conic nuts (Item 10,
NSN list) attaching the
retention assembly to
the helmet shell (Item
11, NSN list), noting
the position of
components.

SCREWS

Figure 31. Retention Hardware Locations

43

TM 08744B-12&P
b.

Installation
(1) Position the new retention assembly (Item 5, NSN List) in the helmet in the
same manner as the old one, ensuring that the nape pad is in the rear.
NOTE
Before installing screws, apply a small amount of thread-locking adhesive
(Item 1, Consumable Items List) to the threads of each screw.
(2) Refer to Figure 32. On one side of the
helmet, position the rear attachment
RETENTION
CONIC
point of the retention assembly against
ASSEMBLY
the helmet shell. Install a conic nut
NUT
ATTACHMENT
into the hole in the retention assembly.
POINT
On the outside of the helmet, install
and tighten a screw into the conic nut.
Repeat this step for the front retention
attachment point on the same side.
(3) Repeat Step 2 to attach the other two
retention assembly attachment points
SCREW
to the helmet.
(4) Don the helmet, check the fit as in
Figure 32. Retention Assembly
Paragraph 3.4, and make any
and Hardware
necessary adjustments.

44

TM 08744B-12&P
4.4.3 Replacing Pad Suspension
NOTE
One side of each pad has printing. ONLY THE PRINTED SIDE OF THE PAD
WILL ATTACH TO THE HOOK DISKS ON THE HELMET. Press the pad against
the hook disks.
a.

Removal
(1) Note the arrangement of pads in the helmet.
(2) Pull the individual pads off the hook disks inside the helmet.

b.

Installation
Press the replacement pads (Item 2 or 3, NSN List) against the hook disks in
the same arrangement as noted in Step 1. (See Paragraphs 3.4.3, 3.4.3.1, and
3.4.3.2 for Pad Configurations and Pad Suspension Adjustment.)

45

TM 08744B-12&P
4.4.4 Replacing Hook Disks
This procedure describes the replacement of one or more hook disks inside the
helmet.
a.

Removal
(1) Remove the old/damaged hook disk(s).
(2) Clean the inside of the helmet shell
with isopropyl alcohol (Item 2,
Consumable Items List) where each
hook disk was removed. Allow to dry
thoroughly.

b.

Installation
Referring to Figure 33, press the new
hook disk(s) (Item 4, NSN List) firmly
to the inside of the helmet shell in
approximately the same location(s)
as the old ones.

46

Figure 33. Approximate Location

of Hook Disks

TM 08744B-12&P
4.5 Retrofitting the Helmet (Removing
Headband/Crown Pad Suspension and
Installing Pad Suspension)
If your helmet has a headband/crown pad
suspension (Figure 34), you must retrofit the
helmet to a pad suspension (Figure 35). This
requires (1) removing the headband/crown pad
suspension and the existing retention, (2)
cleaning the inside of the helmet shell, (3)
installing hook disks, (4) plugging the front
and rear attachment holes (which will no
longer be used), (5) installing a new retention
assembly, and (6) installing the pad suspension
system.
(Note: If your existing retention has two
attachment holes in each strap, note which
holes are used. You may continue using this
retention until it is no longer serviceable.)
Follow the procedure outlined in Paragraphs
4.5.1 through 4.5.6, beginning on the next page.

CROWN PAD

RETENTION
SUSPENSION
HEADBAND

Figure 34. Headband/Crown Pad

Suspension
PAD SUSPENSION
RETENTION

HOOK DISK

Figure 35. Pad Suspension

47

TM 08744B-12&P
4.5.1 Removing the Headband/Crown Pad Suspension

WARNING
When you perform Step 1, discard all six screws and the four side A-nuts;
do not reuse them. They do not provide the same level of protection as the
replacement hardware. (However, keep the center front and center rear
A-nuts; you will use them to plug the center front and center rear holes.)
(1) Using a " flat-tip
screwdriver, remove the six
screws (shown in Figure 36)
and A-nuts attaching the
headband/crown pad
suspension and retention to
the helmet shell.
(2) Remove the
headband/crown pad
suspension and retention
from the helmet.

SIDE SCREWS

CENTER
FRONT
SCREW

CENTER
REAR
SCREW

Figure 36. Hardware Locations

48

TM 08744B-12&P
4.5.2 Cleaning the Inside of the Helmet
(1) Clean the inside of the helmet with isopropyl alcohol (Item 2, Consumables
List).
(2) Allow the helmet to air-dry.
4.5.3 Installing Hook Disks
Press the new hook disks (Item 4, NSN
List) firmly to the inside of the helmet shell.
Space the disks as evenly as possible.
Do not cover the two ear sections or the
six screw holes.
Figure 37 shows a typical disk arrangement
for size Medium. Use the correct number of
disks for your helmet size as follows:
X-Small:
Small:
Medium:
Large:
X-Large:
XX-Large

22
23
24
27
32
35

Figure 37. Hook Disks Installed in Helmet

(Typical Arrangement for Size Medium)
49

TM 08744B-12&P
4.5.4 Plugging Front and Rear Holes
in Helmet

WARNING

SCREW

A-NUT

Use only the screws and A-nuts

described below.
For the wearer's safety, ensure that the
screws do not protrude through the
A-nuts when installed.
Referring to Figure 38, do the following:
(1) Install a screw (Item 7, NSN List)
and an A-nut (Item 8, NSN List)
into the center front hole of the
helmet shell.
(2) Install a screw (Item 7, NSN List)
and an A-nut (Item 8, NSN List)
into the center rear hole in the
helmet shell.
50

A-NUT

SCREW

Figure 38. Holes to Be Plugged

TM 08744B-12&P
4.5.5 Installing New Retention
(1) Position the retention assembly (Item 6,
NSN List) in the helmet, ensuring that the
nape pad is in the rear.
NOTE
Before installing screws, apply a small amount
of thread-locking adhesive (Item 1, Consumable
Items List) to the threads of each screw.
(2) Refer to Figure 39. At each of the four
attachment points, do the following:
a. Position the retention assembly
(Item 5, NSN List) against the inside
of the helmet.
b. Install a conic nut (Item 10, NSN List) into
the hole in the retention assembly. Ensure
that the slotted end of the conic nut faces
inward.
c. On the outside of the helmet, install and
tighten a screw (Item 9, NSN List) into
the conic nut.

RETENTION
ASSEMBLY
ATTACHMENT
POINT

CONIC
NUT

SCREW

DETAIL

SCREWS

Figure 39. Attachment Points

51

TM 08744B-12&P
4.5.6 Installing Pad Suspension
(1) Press the pads (Item 2
or 3, NSN List) against
the hook disks in the
arrangement shown in
Figure 40. This is the
standard seven-pad
configuration.
(2) Proceed to Paragraphs
3.3 through 3.4 to
check the fit of the
helmet and make any
necessary adjustments.

Figure 40. Standard Seven-Pad Configuration

52

TM 08744B-12&P
5. NATIONAL STOCK NUMBERS (NSN) LIST
ITEM NUMBER

DESCRIPTION

Lightweight Helmet

SIZE

NSN

X-Small

8470-01-560-2866

Small

8470-01-560-3267

Medium

8470-01-560-3076

Large

8470-01-560-3270

X-Large

8470-01-560-3271

XX-Large

8470-01-560-3272

Pad Set, inch

All sizes

8470-01-546-9420

Pad Set, 1 inch ( inch crown)

All sizes

8470-01-476-5648

Hook Disk

All sizes

8470-01-506-6742

X-Small, Small

8470-01-560-3033

Medium, Large

8470-01-560-3043

X-Large

8470-01-560-3061

XX-Large

8470-01-560-3072

Retention Assembly

53

TM 08744B-12&P
NSN LIST (Continued)
ITEM NUMBER

DESCRIPTION

SIZE

NSN

Chinstrap

All Sizes

8470-01-560-3549

Screw (center front

and center rear)

All Sizes

8470-01-494-5989

A-nut (center front

and center rear)

All Sizes

8470-01-494-5990

Shoulder Screw (retention)

All Sizes

8470-01-551-2480

10

Conic Nut (retention)

All Sizes

8470-01-541-9320

X-Small

TBD

Small

TBD

Medium

TBD

Large

TBD

X-Large

TBD

XX-Large

TBD

11

54

Helmet Shell

TM 08744B-12&P
NSN LIST (Continued)
ITEM NUMBER

12

13

DESCRIPTION

Helmet Cover

Nape Protection Pad (NAPP),

Coyote Brown 498

SIZE

NSN

X-Small, Small

8415-01-549-4944

Medium, Large

8415-01-549-4946

X-Large

8415-01-549-4948

XX-Large

TBD

All Sizes

8470-01-554-6751

6. CONSUMABLE ITEMS LIST

ITEM NUMBER

DESCRIPTION

Thread-locking Adhesive (local purchase;

Loctite 222MS recommended)

Isopropyl Alcohol (local purchase)

55

TP0187-17

FEBRUARY 2008