TM - 1 1680 377 13&P 1 - HGU 56 - Mar - 12 1 PDF
TM - 1 1680 377 13&P 1 - HGU 56 - Mar - 12 1 PDF
TM - 1 1680 377 13&P 1 - HGU 56 - Mar - 12 1 PDF
T.O. 14P3-4-201
NAVAIR 13-1-6.7-3-1
TECHNICAL MANUAL
*TM 1-1680-377-13&P-1 dated 23 March 2012 supersedes TM 1-1680-377-13&P-1 dated 09 October 2009, including all changes.
DISTRIBUTION STATEMENT C Distribution authorized to U.S. Government agencies and their contractors to protect technical or operational
information.to protect critical technology This determination was made on 2 January 2002. Other requests for this document will be referred to:
Department of the Army, Program Executive Office, Aviation, Air Warrior, ATTN: SFAE-SDR-AW, Redstone Arsenal, Alabama 35898.
DESTRUCTION NOTICE Destroy by any method that will prevent disclosure of contents or reconstruction of the document.
WARNING SUMMARY
This warning summary contains safety warnings that must be understood and applied during operation and mainte-
nance of the Air Warrior system. Failure to observe these warnings could result in serious injury or death to personnel.
For information concerning First Aid refer to FM 4-25.11.
AIRCREW INTEGRATED HELMET SYSTEM (AIHS) WARNINGS
The following warnings are for the Air Warrior Aircrew Integrated Helmet System (AIHS).
WARNING
When donning helmet, ensure that nape strap pad is completely pulled down and that the
keeper tab is taut. Failure to do so will decrease helmet stability and may cause injury to the
wearer.
WARNING
Do not force the earplug into the ear. This may cause the foam tip to be pushed back,
exposing the plastic tube inside. This will diminish hearing protection and may cause
injury to the ear canal.
Ensure that the proper foam tip is attached to each earplug before inserting the earplug
into the ear. If proper foam tip is not attached to each earplug, may cause injury to the ear
canal.
WARNING
Ensure that the volume level of the audio sent to the CEP is reduced. Damage to the wearers
ears may result if the volume level is not reduced.
WARNING
ALWAYS wear the helmet with the chin-strap properly attached and adjusted. Failure to secure
the chin strap will decrease helmet stability and may cause injury to the wearer.
a
TM 1-1680-377-13&P-1
WARNING
WARNING
When using the anti-fogging solution described below, avoid getting the liquid solution into the
eyes. Solution will irritate and may burn the eyes. In case of eye contact, flush with fresh water
for 15 minutes. Contact physician if irritation persists. See package for other directions.
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WARNING
Do not repair or use any helmet that is damaged beyond the limits set forth in the PMCS charts.
Injury or death may result if you do.
WARNING
Do not remove any plastic layer form the lining, helmet, shock (TPL). Removal of plastic layers
will result in decreased helmet stability and may cause injury or death.
Do not add loose plastic layers to the lining, helmet, shock (TPL). Adding loose plastic layers
will result in decreased helmet stability and may cause injury or death.
WARNING
When the helmet shell is drilled, the drill bit may penetrate the shell very quickly. To avoid injury,
keep hands away from the inside of the helmet when drilling.
WARNING
Wear eye-protective goggles when drilling holes in helmet to prevent eye injury.
When drilling helmet, use the 2x4 block of wood to prevent hand injury.
WARNING
Wear eye-protective goggles when trimming the MFS, chips from the MFS may injure the
eyes.
Wear a respirator when trimming the MFS, harmful airborne particles may be inhaled.
WARNING
Exercise care when using the soldering gun, burns can cause serious burns or death.
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TM 1-1680-377-13&P-1
WARNING
Chin strap must be adjusted securely under the Operator/Wearers chin at all times when
the helmet is worn. DO NOT allow the oxygen mask to be placed between the strap and the
Operator/Wearers chin; warn the Operator/Wearer not to fasten the chin strap over the oxygen
mask. Failure to heed this warning will result in a loss of helmet stability and may cause injury to
the Operator/Wearer.
WARNING
To minimize health risks and safety concerns, always wear eye protective goggles and a
respirator (and appropriate protective clothing when sanding, mixing or spraying primer or
paint.
WARNING
Do not position the tap connectors between the earphone element and earcup wall, doing so
could affect lateral impact protection.
WARNING
It is imperative that each crewmember is familiar with the donning, fitting, care, and operation of
the CEP system used in the aircraft. Failure to complete the following procedures could result
in personal injury to the crewmember.
WARNING
To prevent injury to the ears, turn the volume settings of your ICS radio to a lower position before
you plug your helmet into the communication system. From the low, volume setting, raise
volume and adjust to desired level.
d
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The following warnings are for the Air Warrior Primary Survival Gear Carrier (PSGC).
WARNING
Utilization of PSGC Leg Straps is Mandatory. Failure to properly secure leg straps will degrade
the PSGC extraction/restraint capabilities and may result in serious personal injury.
WARNING
Do not place survival items on the back, aligned with the spine of the wearer, this may cause
spinal injuries during a crash sequence.
WARNING
In a Nuclear, Biological, and Chemical (NBC) environment, DO NOT use water or attempt to
drink from the water storage bag. DESTROY the bag and contents. It CANNOT be decontami-
nated.
WARNING
Ensure familiarity with medicine dosing prior to takeoff. Unfamiliarity of medication can cause
injury to crewmember.
WARNING
Safety Restraint Tether (SRT) is for external attachment to helicopter only. The SRT is not rated
for hoisting, crewmember may be injured.
WARNING
Do not point a loaded launcher at personnel. Distress flares burn at a temperature of 5000
degrees F and can cause serious burns or death.
e
TM 1-1680-377-13&P-1
WARNING
Never approach an operating rotary-wing aircraft from the rear! Death or severe injury
could occur if the pilot does not see you and rotates the aircraft. Always approach an
operating aircraft from the front or side and only when signaled to do so by the pilot or
crewmember. Minimize exposure to the front of any weapons systems.
Pilots must take into consideration lateral center of gravity (CG) when attempting any
externally carried rescue. Pilot must retain enough cyclic force to counter the weight of the
rescuee. Externally carried rescues will be flown the shortest practical distance to remove
the rescuee from immediate extreme danger.
Pilots should limit forward airspeed to 60 knots and only exceed this speed if required by
the tactical situation. Pilots/crew should monitor the status of the rescuee. If the rescue
falls from his/her seating he/she will be retained by the SRT, however the rescuees lower
body/legs may be lower than the landing gear. Ensure he/she is clear of the landing gear
before landing.
The Safety Restraint Tether is ONLY FOR USE IN EMERGENCY SITUATIONS and must
be kept in serviceable condition. Aircrew practice of SRT attachment to the aircraft will
be limited to nonoperating aircraft, parked in an approved landing or tiedown area. The
SRT is intended to be used with the extraction harness of the AIRSAVE and PSGC (or
the SARVIP and the SRU-21/P when modified with extraction harness). Use with other
systems may result in injury.
The Safety Restraint Tether has a rated strength of 3000 pounds and an one-time pull
test strength of 5000 pounds. Do not use the tether if any of the bar tacks is loose, frayed,
or missing. Do not use the tether if the nylon webbing is worn, frayed, cut, or has been
soaked by POL (Petroleum, Oil Lubricant) products. Turn it in and get a new tether.
f
TM 1-1680-377-13&P-1
THE TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 173 AND THE TOTAL NUM-
BER OF WORK PACKAGES IN THIS MANUAL IS 737 CONSISTING OF THE FOLLOWING:
A
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T.O. 14P3-4-201
NAVAIR 13-1-6.7-3-1
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, D.C., 23 March 2012
TECHNICAL MANUAL
DISTRIBUTION STATEMENT C Distribution authorized to U.S. Government agencies and their contractors to protect technical or operational
information. to protect critical technology This determination was made on 2 January 2002. Other requests for this document will be referred to:
Department of the Army, Program Executive Office, Aviation, Air Warrior, ATTN: SFAE-SDR-AW, Redstone Arsenal, Alabama 35898.
DESTRUCTION NOTICE Destroy by any method that will prevent disclosure of contents or reconstruction of the document.
i
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TABLE OF CONTENTS
WP Sequence No.
ENSEMBLE
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Volume 2
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Volume 3
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Volume 4
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MOBILE REFILL SYSTEM FOR THE AQUALUNG SEA (SURVIVAL EGRESS AIR) (MRS III)
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Volume 5
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Volume 6
xix
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BODY ARMOR
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Volume 7
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Volume 8
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This manual covers the functional aspects of the Air Warrior system, including system description, safety, disassembly,
assembly, operation interface, field operations, data recording, field maintenance and support.
The Air Warrior manual is organized into 8 Volumes and each volume is made up of numbered chapters. The chap-
ters divide the TM into major components that comprise the Air Warrior system and then into specific functional infor-
mation for that component such as: General Information, Operating Instructions, Troubleshooting Information, Main-
tenance Information, Parts and Supporting Information. Each of the chapters is then divided into multiple Work Pack-
ages (WPs).
The Table of Contents (TOC) lists the operator and maintenance tasks for Air Warrior. Each volume has its own TOC,
except for Volume 1 which contains a TOC for the entire Air Warrior system.
Status of work package revisions is found in the List of Effective Pages preceding the Table of Contents.
USE OF SHALL, SHOULD, AND MAY
Within this technical manual, the word shall is used to indicate a mandatory requirement. The word should is used to
indicate non-mandatory but preferred method of accomplishment. The word may is used to indicate an acceptable
method of accomplishment.
Work Packages are intended to be all-inclusive miniature "books" that contain all the information required to complete
a task: Initial Setup (Tools and Special Tools, Materials/Parts, References), required steps/paragraphs, figures, and
tables. All task descriptions will lead the user step-by-step through the procedure. Before beginning a task, the user
should read through the procedure completely to determine the procedures goal, then go back and follow the steps as
written.
There is a Repair Parts Special Tools List (RPSTL) for each major component of the Air Warrior system. Each vol-
ume of Air Warrior will contain more than one RPSTL. The RPSTL is comprised of Introduction work package and the
RPSTL itself which is divided into the following work packages.
REPAIR PARTS LIST WORK PACKAGES - Work packages containing lists of spares and repair parts au-
thorized by this RPSTL for use in the performance of maintenance. These work packages also include parts
which must be removed for replacement of the authorized parts. Parts lists are composed of functional groups
in ascending alphanumeric sequence, with the parts in each group listed in ascending figure and item number
sequence.
SPECIAL TOOLS LIST WORK PACKAGES - Work packages containing lists of special tools, special TMDE,
and special support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in the
DESCRIPTION AND USABLE ON CODE (UOC) column).
CROSS-REFERENCE INDEXES WORK PACKAGES - There are two cross reference indexes work packages
in this RPSTL: the National Stock Number (NSN) Index work package and the Part Number (P/N) Index work
package. The National Stock Number Index work package refers you to the figure and item number. The Part
Number Index work package refers you to the figure and item number.
xxviii
TM 1-1680-377-13&P-1
WARNING
A procedure, practice, or condition, etc. that may result in injury or death if not carefully observed
or followed.
CAUTION
A procedure, practice, or condition, etc. that may damage equipment if not carefully observed
or followed.
NOTE
xxix/xxx blank
TM 1-1680-377-13&P-1
CHAPTER 1
GENERAL INFORMATION,
EQUIPMENT DESCRIPTION AND THEORY OF OPERATION
FOR
ENSEMBLE
ENSEMBLE
PART NO. 1005802-1 NSN 1680-01-510-1596 EIC: H7A
GENERAL INFORMATION
SCOPE
Purpose of Equipment. The Air Warrior Ensemble is a suite of Aviation Life Support Equipment (ALSE) that increase
the survivability of aircrew in rotary and fixed wing aircraft.
The Air Warrior Ensemble includes:
0001 00-1
0001 00 TM 1-1680-377-13&P-1
0001 00-2
TM 1-1680-377-13&P-1 0001 00
LIST OF ABBREVIATIONS/ACRONYMS
Term Definition
ALSE Aviation Life Support Equipment
AMSS Aircraft Modular Survival System
ANVIS Aviators Night Visioning Image System
ASI Additional Skill Identifier
AVIM Aviation Intermediate Maintenance
AVUM Aviation Unit Maintenance
A2CU Army Aircrew Combat Uniform
BII Basic Issue Items
BAOS Body Armor Overlay System
CAGEC Commercial and Government Entity Code
COEI Components of End Item
CB Chemical Biological
CPC Corrosion Prevention and Control
DA PAM Department of the Army Pamphlets
EEP Extended Equipment Pouch
EIR Equipment Improvement Recommendations
FM Field Manual
LPFC Low Profile Flotation Collar
HOS Helicopter Oxygen Systems
IABDU Improved Aircrew Battle Dress Uniform
L-QD Liquid Quick Disconnect Assembly
MAC Maintenance Allocation Chart
MCG Microclimate Cooling Garment
MCS Microclimate Cooling System
MCPU Modified Chemical Protective Undergarment
MCU Aircraft Mounted Cooling Unit
MTOE Modified Table of Organization and Equipment
NBC Nuclear, Biological, and Chemical
NSN National Stock Number
ODS Ozone Depleting Substances
OWGC Over Water Gear Carrier
PSGC Primary Survival Gear Carrier
QRSB Quick Release Safety Buckle
RCM Reliability Centered Maintenance
RPSTL Repair Parts and Special Tools List
SBA Soft Body Armor
S.E.A. Survival Egress Air
TAMMS-A The Army Maintenance Management System - Aviation
TMDE Test, Measurement, and Diagnostic Equipment
UBD Underwater Breathing Device
CALIBRATION
Components, accessories, or instruments that require calibration can be found in the separate item sections of this
manual.
ENSEMBLE
PART NO. 1005802-1 NSN 1680-01-510-1596 EIC: H7A
MS100337A
0002 00-1
0002 00 TM 1-1680-377-13&P-1
MS098722C
MS098818C
0002 00-2
TM 1-1680-377-13&P-1 0002 00
MS040477
MS038631
0002 00-3
0002 00 TM 1-1680-377-13&P-1
MS038630
MS038633
MS038632
0002 00-4
TM 1-1680-377-13&P-1 0002 00
MS038636
MS038635
0002 00-5
0002 00 TM 1-1680-377-13&P-1
MS098718A
MS098719A
0002 00-6
TM 1-1680-377-13&P-1 0002 00
MS098721A
0002 00-7
0002 00 TM 1-1680-377-13&P-1
0002 00-8
TM 1-1680-377-13&P-1 0002 00
Key Description
R Required for all aircrew at all times.
1 Soft armor to be worn in hostile fire areas.
2 Hard armor (front) to be worn in hostile fire areas requiring greater than small arms protection.
3 Hard armor (back) to be worn by non-rated aircrew in hostile fire areas requiring greater than small
arms protection.
4 Required for all aircrew using CB blower as required by mission (Except AH-64 Apache).
5 Pistol use as directed when issued.
6 OH-58D aircrew only.
7 As required by mission.
8 Lumbar support optional as desired by aircrew.
9 Optional as desired by aircrew.
10 As required per AR 95-1 (Flight Regulations).
EQUIPMENT DATA
CHAPTER 2
OPERATOR INSTRUCTIONS
FOR
ENSEMBLE
OPERATOR INSTRUCTIONS
ENSEMBLE
PART NO. 1005802-1 NSN 1680-01-510-1596 EIC: H7A
OPERATOR INSTRUCTIONS
ENSEMBLE
PART NO. 1005802-1 NSN 1680-01-510-1596 EIC: H7A
INITIAL SETUP:
NA
OPERATOR INSTRUCTIONS
ENSEMBLE
PART NO. 1005802-1 NSN 1680-01-510-1596 EIC: H7A
INITIAL SETUP:
NA
UNUSUAL ENVIRONMENT/WEATHER
There are no operation under unusual conditions
CHAPTER 3
AVIATION UNIT MAINTENANCE INSTRUCTIONS
FOR
ENSEMBLE
INITIAL SETUP:
References References (cont.)
WP 0256 00
WP 0541 00 WP 0327 00
WP 0274 00 WP 0077 00
WP 0604 00 WP 0013 00
CHAPTER 4
SUPPORTING INFORMATION
FOR
ENSEMBLE
SUPPORTING INFORMATION
ENSEMBLE
PART NO. 1005802-1 NSN 1680-01-510-1596 EIC: H7A
REFERENCES
SCOPE
This lists all forms and publications referenced in this manual and required by the user to maintain the Air Warrior En-
semble.
ARMY REGULATIONS (AR)
SUPPORTING INFORMATION
ENSEMBLE
PART NO. 1005802-1 NSN 1680-01-510-1596 EIC: H7A
SUPPORT ITEMS
CHAPTER 5
GENERAL INFORMATION,
EQUIPMENT DESCRIPTION AND THEORY OF OPERATION
FOR
HELMET SYSTEM, AIRCREW INTEGRATED
(HGU-56/P)
SCOPE
Type of Manual Operator and Aviation Unit Maintenance Manual.
Equipment Name and Model Number There is no Integrated Helmet Unit (IHU) model number.
Purpose of Equipment To provide a custom fitted helmet affording acoustic, eye, and head protection for aircrew per-
sonnel.
MAINTENANCE FORMS, RECORDS, AND REPORTS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as ap-
plicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual; DA PAM 738-751,
Functional Users Manual for the Army Maintenance Management System - Aviation (TAMMS-A); or AR 700-138, Army
Logistics Readiness and Sustainability.
IHADSS inspection record keeping will be accomplished by Aviation Life Support Equipment (ALSE) personnel.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
If your Aircrew Integrated Helmet System needs improvement, let us know. Send us an EIR. You, the user, are the only
one who can tell us what you do not like about your equipment. Let us know why you do not like the design or perfor-
mance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to follow the in-
structions and links below:
For ALL non-Aviation/Missile Warranty, EIR and PQDRs must be submitted through the Web Product Quality Defi-
ciency Reporting (PQDR) site. Note that all CECOM managed (B16), including aviation, items must also be submitted
through the following site. The Web PQDR Web site is: http://www.nslcptsmh.csd.disa.mil/webpqdr/webpqdr.htm .
New accounts can be established at the following address: http://www.nslcptsmh.csd.disa.mil/accessforms/uar-
form.htm .
All AMCOM (Aviation and Missile Command) Deficiency Reports (DRs), (Warranty, EIR, and PQDRs) must be submit-
ted through the Joint Deficiency Reporting System (JDRS) at https://jdrs.mil/DR_Initiate.cfm?service=AR .
You may also submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368
using e-mail, regular mail, or fax using the addresses/fax numbers specified in (DA PAM 750-8, The Army Maintenance
Management System (TAMMS) Users Manual OR DA PAM 738-751, Functional Users Manual for the Army Mainte-
nance Management Systems - Aviation (TAMMS-A) for aviation systems). We will send you a reply.
CORROSION PREVENTION AND CONTROL (CPC)
Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion
problems with this item be reported so that the problem can be corrected and improvements can be made to prevent
the problem in future items.
While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such
as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion prob-
lem.
If a corrosion problem is identified, it can be reported using SF 368. Use of key words such as "corrosion," "rust," "de-
terioration," or "cracking" will ensure that the information is identified as a CPC problem.
The form should be submitted to the address specified in DA PAM 738-751.
OZONE DEPLETING SUBSTANCES (ODS)
The continued use of ODS has been prohibited by Executive Order 12856 of 3 August 1993. The use of ODS in Army
IETMs is prohibited. A listing of these substances will be provided by the acquiring activity.
0009 00-1
0009 00 TM 1-1680-377-13&P-1
LIST OF ABBREVIATIONS/ACRONYMS
Term Definition
AAI Additionally Authorized Items
AIHS Aircrew Integrated Helmet System
ALSE Aviation Life Support Equipment
ANVIS Aviators Night Vision Imaging System
AWIS Aircraft Wireless Intercom System
BII Basic Issue Items
CB Chemical-Biological
CEP Communication Ear Plug
CEPS Communication Enhancement and Protection System
COEI Components of End Item
DAP Digital-to-Analog Processor
DVA Dual Visor Assembly
EAL Energy-Absorbing Liner
FD/LS Fault Detection and Location System
FLIR Forward Looking Infrared Radar
HDU Helmet Display Unit
IEA Integrated Electronics Assembly
IHADSS Integrated Helmet and Display Sighting System
IHU Integrated Helmet Unit
MAC Maintenance Allocation Chart
0009 00-2
TM 1-1680-377-13&P-1 0009 00
Additional Equipment
NOTE
The Cobra dual visor and AH-1 Cobra sight modules are Modified Table of Organization
and Equipment (MTOE) property and will remain with the unit.
The helmet remains with the aviator and is accounted for by the aviator as clothing and
equipment.
In addition, the AIHS supports the integration of various equipment and modules, such as:
Cobra dual visor system module, which features a mounting area for the AH-1 Cobra helmet sighting system
and offset ANVIS mount
Laser-protective visors
ANVIS goggles, which afford enhanced vision for night flying
MBU-12/P oxygen mask cowling device
TEMPEST communications system
Lip Light
Maxillofacial Shield (MFS)
Communication Ear Plugs (CEP)
Communication Enhancement and Protection System (CEPS)
Portable Helicopter Oxygen Delivery System (PHODS)
Weight
The AIHS weighs approximately 3 lbs (1.38 kg.). This weight includes the following subassemblies:
Helmet shell
Chin strap and nape strap pad
Shell, Earphone Assembly
Energy-Absorbing Liner (EAL) and Thermoplastic Liner (TPL)
Communication system
Dual-visor Assembly
0010 00-1
0010 00 TM 1-1680-377-13&P-1
SIZE LENGTH inches (cm) WIDTH inches (cm) HEIGHT inches (cm)
S 9.3 (23.7) 10.6 (26.9) 9.5 (24.1)
M 9.6 (24.5) 10.7 (27.2) 9.6 (24.4)
L 9.9 (25.2) 10.8 (27.4) 9.7 (24.9)
XL 10.2 (26.0) 10.9 (27.7) 9.8 (24.9)
0010 00-2
TM 1-1680-377-13&P-1 0010 00
EQUIPMENT CONFIGURATION
The compatibility of the AH-1 Cobra gunsight, ANVIS, oxygen mask and CB mask is shown in Table 3.
OXYGEN (MBU-12/P)
M45 CB MASK
X - INDICATES COMPATIBILITY
AH-1 Cobra GUNSIGHT X1 X X
NIGHT VISION (ANVIS) X1 X X
OXYGEN (MBU-12/P) X X
M45 CB MASK X X
1 Offset ANVIS goggles and the AH-1 Cobra gunsight may be installed on the same helmet, but only one
may be used at a time.
0010 00-3
0010 00 TM 1-1680-377-13&P-1
6
1
3
MS098856A
2
0010 00-4
TM 1-1680-377-13&P-1 0010 00
1 2 3 4
17
16 6
15 8
14 9
13
10
11
CANAL TIPS
12
MS040354
0010 00-5
0010 00 TM 1-1680-377-13&P-1
0010 00-6
TM 1-1680-377-13&P-1 0010 00
EQUIPMENT DATA
N/A
THEORY OF OPERATION
THEORY OF OPERATION
Helmet Shell
Constructed of graphite and polyethylene, the helmet shell (Figure 1) protects the head from impact and sharp objects.
MS098858A
2 3
EAL TPL
MS098859A
Figure 2. EAL/TPL.
0011 00-1
0011 00 TM 1-1680-377-13&P-1
Zeta II Liner
The Zeta II Liner is a self-molding fit system for the HGU and SPH series flight helmets, and the parachutist helmet. The
multi-layer construction of the Zeta II Liner consists of a core of visco-elastic foam covered with a fabric designed to ad-
here to hook fastening strips on the helmets EAL surface and a perspiration wicking fabric on the scalp surface. Once
donned by the crewmember, the foam core of the system reacts to body temperature, forming to the individual cranial
shape. The wicking nature of the inner fabric and the cooling qualities of the confor foam eliminated perspiration prob-
lems while reducing skin temperature 1.5 degrees F.
TOP
BACK
FRONT
BOTTOM
MS100114
0011 00-2
TM 1-1680-377-13&P-1 0011 00
Retention Assembly
The retention assembly consists of two earcup retaining pads, a nape strap pad, and a chin strap.
Earcup Retaining Pads. The earcup retaining pads (Figure 4, Item 1) support the earcups and the earcup
spacer pads.
Nape Strap Pad. The nape strap pad (Figure 4, Item 2) is located at the inside rear of helmet (beneath TPL),
improves helmet stability by reducing forward rotation.
Chin Strap. Constructed of nylon webbing reinforced with aramid tape, the chin strap (Figure 4, Item 3) assists
in holding the helmet in place.
2
3
MS116141
Earcups
Each earcup (Figure 5, Item 3 and Figure 5, Item 9) is attached to an earcup retaining pad (Figure 5, Item 10). Spacer
pads (Figure 5, Item 11 and Figure 5, Item 12) may be installed behind each earcup retaining pad (against the helmet
shell) if needed to improve earcup fit. Earseals (Figure 5, Item 5) provide comfort and sound attenuation.
Communication System
The AIHS communication system consists of the following:
A pair of earphones (Figure 5, Item 7), one tucked inside each receiver retainer (Figure 5, Item 6) and backed by
a filler pad (Figure 5, Item 8).
A communications cord (Figure 5, Item 4), attached to the outside of the earcups and microphone and anchored
to the helmet shell.
A boom swivel assembly (Figure 5, Item 2), located on the left side of the helmet, serves as the mount for the
boom and microphone (Figure 5, Item 1).
0011 00-3
0011 00 TM 1-1680-377-13&P-1
2
1
3
7 6 5
10 9 8
12 11
MS098861A
1 2
6 5
MS098958A
0011 00-4
TM 1-1680-377-13&P-1 0011 00
MICROPHONE
CEPS BLACK
MODULE WIRE
GAIN/VOLUME WHITE
SWITCH WIRE
BATTERY QUICKDISCONNECT
BLACK
HOLDER INTERFACE
WIRE
WHITE
WIRE
QUICKDISCONNECT CEPS
MODULE BATTERY
INTERFACE
PACK
MS116082
0011 00-5
0011 00 TM 1-1680-377-13&P-1
MS098862A
MS100410A
0011 00-6
TM 1-1680-377-13&P-1 0011 00
Laser-Protective Visors
The laser-protective visors (Figure 10, Item 1 and Figure 10, Item 2) can be used with either the ANVIS or the Cobra
dual visor assemblies. Included are an inner (light green, 2-notch, night-use) visor (Figure 10, Item 2) and an outer
(bronze, 3-notch, day-use) visor (Figure 10, Item 2).
1
2 MS098864A
MS098865A
0011 00-7
0011 00 TM 1-1680-377-13&P-1
TEMPEST Headset
The TEMPEST headset provides shielded communications. This system uses existing AIHS earcups and earphones.
MS098866A
Restrictor, Vision
is the restrictor, vision (Figure 13) which is used in flight training. It blocks the crewmembers side vision, thus forcing
the crewmember to focus on the instrument panel.
MS098868A
0011 00-8
TM 1-1680-377-13&P-1 0011 00
3
MS098869A
ADAPTER
MS098870A
0011 00-9
0011 00 TM 1-1680-377-13&P-1
Adapter, Microphone
The adapter, microphone (Figure 16) provides an interface between the M45 mask and the TEMPEST communica-
tions system. A switch on the adapter plug allows the operator/wearer to select the helmet boom microphone or the
mask microphone without having to disconnect from the aircraft communications system.
ADAPTER
MS098871A
MS098872A
0011 00-10
TM 1-1680-377-13&P-1 0011 00
Intercommunication Unit
The Intercommunication Unit (ICU) (Figure 18) provides a means of communication for dismounted aviators wearing
the CB mask and for testing the communication system on the HGU-56/P helmet. It is powered by a 9-volt battery and
has a clip and hook that can be used to carry the unit. A four-position switch provides for control of communication. The
four positions are as follows:
HARDWIRE
TALK/LISTEN
LISTEN ONLY
OFF
FOURPOSITION SWITCH
MS038668
0011 00-11
0011 00 TM 1-1680-377-13&P-1
Maxillofacial Shield
The maxillofacial shield (MFS) protects the lower facial area from flying debris. Latches (Figure 19) on the right and left
sides of the MFS attach it to the helmet-mounted strikers (Figure 19). The MFS is designed to match the contour of the
visors when either visor is deployed.
STRIKERS
LATCHES
MS098956A
Lip Light
Lip lights green and white LEDs have a bright narrow beam to help keep stray light from interfering with another pilots
vision (side scatter). ML-8, uses three green LEDs. ML-14, uses two green LEDs and one Xenon lamp for brightness
and has a toggle switch. ML-18, uses three white LEDs. Lip lights preserve dark adaptation, uses two AA batteries, and
is installed on the boom microphone, or equivalent microphone. Lip lights have a PUSH ON-PUSH OFF switch that can
be actuated by the lip or tongue. A slight push on the switch causes momentary light, while a further push keeps the light
on until another push by the lip or tongue turns the light off.
0011 00-12
TM 1-1680-377-13&P-1
CHAPTER 6
OPERATOR INSTRUCTIONS
FOR
HELMET SYSTEM, AIRCREW INTEGRATED
(HGU-56/P)
OPERATOR INSTRUCTIONS
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
CONTROLS AND INDICATORS
MS098874A
0012 00-1
0012 00 TM 1-1680-377-13&P-1
Chin Strap
The chin strap (Figure 2, Item 5) is attached to the helmet at the right-hand earcup retaining pad. A double D-ring
(Figure 2, Item 3) allows for one-handed adjustment. Tightening the chin strap will also tighten the earcups.
Nape Strap
The nape strap pad (Figure 2, Item 1) features an adjustable cross strap that feeds through two webbing loops, which
are linked to straps extending from each earcup retaining pad. This construction allows the nape strap pad and the ear-
cups to be adjusted at the same time via the adjustment straps (Figure 2, Item 4). A tie-down strap (Figure 2, Item 2)
extending from the top of the nape strap pad secures the nape strap pad to the helmet shell through a cutout in the EAL.
The earcup pads (Figure 2, Item 6) provide an attachment area for the earcups.
6
2
4
5
3 MS100428A
2
3
MS098876
0012 00-2
TM 1-1680-377-13&P-1 0012 00
3
MS098845A
0012 00-3
0012 00 TM 1-1680-377-13&P-1
CAUTION
Ensure that the ANVIS system mounted on your HGU-56/P is working properly in accordance
with TM 11-5855-263-10 prior to using it. Failure to check the ANVIS or to be able to see the low
battery warning light when using the ANVIS may result in a critical loss of equipment use.
The V-1 ANVIS center-mount AN/AVS-6(V) 1 (Figure 5, Item 4) attaches to the dual visor housing (Figure 5, Item 1)
through pre-drilled holes. From this location, the AN/AVS-6 (Figure 5, Item 3) can be deployed or stowed. When the
ANVIS is in the stowed position, either visor can be deployed. The ANVIS power pack is mounted to the rear of the
helmet with hook and pile fastener. The electrical connection is made at the rear of the cover, access (Figure 5, Item
2). (The cover, access houses the ANVIS cable.) For ANVIS operational and maintenance information, refer to TM
11-5855-263-10.
1
3
MS098846A
CAUTION
Ensure that the ANVIS system mounted on your HGU-56/P is working properly in accordance
with TM 11-5855-263-10 prior to using it. Failure to check the ANVIS or to be able to see the low
battery warning light when using the ANVIS may result in a critical loss of equipment use.
The AN/AVS-G(V)2 goggles (not shown in the figure) attach to the offset ANVIS mount (Figure 5, Item 3). The mount
is attached to the Cobra housing (Figure 6, Item 1) via pre-drilled holes. The goggles are stowed, deployed, and con-
nected in the same manner as the centermount ANVIS.
0012 00-4
TM 1-1680-377-13&P-1 0012 00
NOTE
When the AH-l helmet sighting system and the offset-mount ANVIS are both mounted on
the housing, only one of these systems can be deployed at any given time.
When a Cobra aircrew reports to a Cobra unit, the AH-l helmet sighting system module will
be mounted on the helmet. When the aviator leaves the unit, the module will be removed.
The basic dual visor assembly will be re-mounted on the helmet, and the AH-l module will
be retained by the unit. The ALSE technician will perform all visor removal and mounting
as well as mounting/demounting of the sighting system module.
The AH-1 Helmet Sighting System module (Figure 6, Item 4) attaches to the Cobra dual visor housing (Figure 6, Item
1) via pre-drilled holes. The sight assembly mount is installed on the visor housing to the right of the center line. The
magnetic coupler (Figure 6, Item 2) is installed on the rear housing arm at the left of the helmet shell center line. Either
visor can be raised or lowered when the sight is deployed. A cable runs along the rear of the housing to the magnetic
coupler.
2
3
4
MS098847A
Figure 6. Cobra Dual Visor Assembly Module with Offset ANVIS Mount and AH-1 Helmet Sighting System Module.
0012 00-5
0012 00 TM 1-1680-377-13&P-1
MS098855A
0012 00-6
TM 1-1680-377-13&P-1 0012 00
1
2
MS100411A
1 3
MS100412A
0012 00-7
0012 00 TM 1-1680-377-13&P-1
Intercommunication Unit
The Intercommunication Unit (ICU) provides a means of communication for dismounted aviators wearing the CB mask
and for testing the communication system on the HGU-56/P helmet. It is powered by a 9-volt battery and has a clip and
hook that can be used to carry the unit. A four-position switch provides for control of communication. The four positions
are as follows:
HARDWIRE
TALK/LISTEN
LISTEN ONLY
OFF
FOURPOSITION SWITCH
MS038668
0012 00-8
TM 1-1680-377-13&P-1 0013 00
OPERATOR INSTRUCTIONS
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
OPERATION UNDER USUAL CONDITIONS FOR DONNING/REMOVING HELMET
INITIAL SETUP:
Personnel Required WP 0016 00
Crew Member EM 0250 Donning Helmet Video
EM 0250 Removing Helmet Video
References
DONNING HELMET
See Donning Helmet Video, EM 0250.
WARNING
When donning helmet, ensure that nape strap pad is completely pulled down and that the
keeper tab is taut. Failure to do so will decrease helmet stability and may cause injury to the
wearer.
CAUTION
When donning or removing helmet, spread helmet just enough to clear head. Excessive
spreading may damage helmet.
1. Hook thumbs over earcups and spread helmet slightly.
2. Position front edge of helmet firmly against forehead; rotate helmet rearward and down onto head.
3. Press helmet down firmly with both hands to ensure that helmet is properly positioned on head.
4. Fasten and adjust chinstrap, WP 0016 00, ADJUSTING CHIN STRAP.
5. Adjust nape strap, WP 0016 00, ADJUSTING NAPE STRAP.
REMOVING HELMET
See Removing Helmet Video, EM 0250.
1. Loosen chinstrap, WP 0016 00, ADJUSTING CHIN STRAP.
2. Hook thumbs over earcups and spread helmet slightly.
3. Rotate helmet off head.
OPERATOR INSTRUCTIONS
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
OPERATION UNDER USUAL CONDITIONS FOR CEP-EQUIPPED HELMETS ONLY
INITIAL SETUP:
Materials/Parts Personnel Required
Foam Tips (WP 0065 00, Figure 2, Item 18) Crew Member
WARNING
Ensure that the proper foam tip is attached to each earplug before inserting the earplug
into the ear. If proper foam tip is not attached to each earplug, may cause injury to the ear
canal.
Do not force the earplug into the ear. This may cause the foam tip to be pushed back,
exposing the plastic tube inside. This will diminish hearing protection and may cause
injury to the ear canal.
4. Compress the foam tip (Figure 1, Item 1) of one earplug to about 1/3 of its original diameter by rolling it
between your thumb and index finger. This will ease insertion into the ear. Do not squeeze the foam tip flat.
When compressing the foam tip, do not allow a crease to form. This will diminish hearing protection.
1
2
MS100413A
0014 00-1
0014 00 TM 1-1680-377-13&P-1
5. Hold the earplug housing (Figure 1, Item 2) between the thumb and index finger on your hand on the same
side as the earplug being fitted. With your other hand, reach behind your head and pull your ear on the same
side as the earplug up and away from your head. This will straighten the ear canal to ease earplug insertion.
Carefully insert the foam tip of the earplug into the ear.
6. Ensure that the earplug is positioned so that the wire rests in the notch at the bottom of the ear canal. Hold
the plug for a few seconds until the foam expands inside the ear and will hold the plug in place.
7. Repeat Steps 4. through 6. for the other earplug.
8. Check the fit for each earplug by moving a cupped hand near the ear. The user should not perceive any
change in sound level. If the sound level changes, this indicates an improper seal; repeat Steps 4. through
6. with new foam tips. If the foam tips still do not seal properly, repeat Steps 4. through 6. with the next larger
foam tip size. If the foam tips still do not seal properly, consult the local hearing conservation center.
NOTE
The CEP extension cable (CEP199-X01) should be used only with a CB protective mask. If
you are NOT wearing a CB protective mask, do not perform Steps 9. through 10.
9. If the M45 mask is to be worn, connect the CEP (Figure 2, Item 1) to the extension cable (Figure 2, Item 2).
Then, don the mask.
MS100415A
10. If the M45 mask is to be worn, connect the extension cable (Figure 3, Item 2) to the helmet connector (Figure
3, Item 1) before donning the helmet.
0014 00-2
TM 1-1680-377-13&P-1 0014 00
3 1
MS100414A
WARNING
Ensure that the volume level of the audio sent to the CEP is reduced. Damage to the wearers
ears may result if the volume level is not reduced.
13. Rotate the aircraft ICS volume level to full OFF.
14. Plug the communications cord into the aircraft ICS. Check for proper operation of the CEP and the receivers
while slowly increasing the volume to a comfortable level.
REMOVING HELMET WITH CEP
1. If the M45 is NOT worn and the extension cable is NOT being used, disconnect the CEP connector end from
the helmet connector before removing the helmet.
2. If you are wearing a CB protective mask, remove the helmet.
a. Disconnect the extension cable from the helmet.
b. Disconnect the extension cable from the CEP after removing the CB protective mask; and proceed
to Step 4.
0014 00-3
0014 00 TM 1-1680-377-13&P-1
CAUTION
Squeezing ear plugs causes them to become misshapen and degrade the effectiveness of the
earplug.
3. Remove the helmet.
NOTE
Do not leave the CEP attached to the helmet when not in use; always store the CEP in the
container provided.
4. Remove each earplug by grasping the housing and pulling the earplug out of the ear.
5. Store the CEP in the container provided.
6. Store the CEP extension cable in a marked container so that it is available when needed.
CARE OF CEP
1. When foam tips become soiled, remove foam tips from earplugs.
NOTE
Do not wash foam tips more than necessary (about once a week). The more often foam tips are
washed the sooner they will wear out.
2. Hand wash foam tips with warm water and mild soap and allow foam tips to air dry.
NOTE
3. Discard foam tips if the foam is degraded or pulled away from the plastic tubes inside.
0014 00-4
TM 1-1680-377-13&P-1 0015 00
OPERATOR INSTRUCTIONS
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
OPERATION UNDER USUAL CONDITIONS FOR COMMUNICATION ENHANCEMENT AND PROTECTION
SYSTEM (CEPS)
INITIAL SETUP:
Materials/Parts Personnel Required
Helmet, Flyers (WP 0065 00, Figure 2) Crew Member
Communication Enhancement and Protection References
System (CEPS) (WP 0065 00, Figure 9, Item 1)
WP 0013 00
Battery, Alkaline, AA (WP 0070 00, Item 29)
NOTE
The CEPS is activated only during ground operations. Turn OFF near operating aircraft or when
plugged into the aircraft ICS.
The following steps should be followed in sequence to properly operate the CEPS.
1. Install two AA Alkaline batteries in the battery holder.
2. Properly insert the single side CEP into ears.
3. Don the HGU-56/P Helmet (WP 0013 00).
4. Plug single side CEP into each helmet interface connector (right on right and left on left).
NOTE
Hearing should be clear and static free, equal on both sides.
5. Turn the CEPS On/Off switch located on the back of the helmet to ON, refer to Figure 1.
0015 00-1
0015 00 TM 1-1680-377-13&P-1
COMMUNICATIONS
JACK
BATTERY
HOLDER ANVIS
CEPS ON/OFF
SWITCH PILE
FASTENER
MICROPHONE
CORD
MS116093
6. Test volume control by momentarily pressing and holding one of the gain control buttons (Figure 2) on the
right side of the helmet.
GAIN CONTROL
BUTTONS GAIN/VOLUME SWITCH
(LOWER EDGE OF RIGHT EARDOME)
MS116079
NOTE
When the buttons are pressed and held, the level will change until the upper or lower limit is
reached. It takes about 8 seconds to go from one limit to the other limit when the button is held.
0015 00-2
TM 1-1680-377-13&P-1 0015 00
NOTE
Always reduce the volume level from the CEPS to minimum volume level when in a noisy
environment.
OPERATOR INSTRUCTIONS
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
OPERATION UNDER USUAL CONDITIONS FOR HELMET ADJUSTMENTS
INITIAL SETUP:
Personnel Required Crew Member
HELMET ADJUSTMENTS
ADJUSTING CHIN STRAP
WARNING
ALWAYS wear the helmet with the chin-strap properly attached and adjusted. Failure to secure
the chin strap will decrease helmet stability and may cause injury to the wearer.
1. Fasten the chin strap by inserting the strap through both D-rings, separating the rings, passing the strap over
the outer ring (Figure 1, Item 1), and inserting the strap back through the inner D-ring (Figure 1, Item 2).
2. To tighten the chin strap, pull on end (Figure 1, Item 3) to attain the desired fit. Tightening the chin strap will
also tighten the earcup fit.
3. To loosen the chin strap:
a. Rotate the outer D-ring up and to the left by pulling on the two tabs of the outer D-ring.
b. Push the strap through the inner D-ring toward the left as needed to loosen or disengage the strap.
c. Pull the section of the strap under the chin to the right.
MS098850A
0016 00-1
0016 00 TM 1-1680-377-13&P-1
NOTE
When the nape strap is centered both nape straps will be the same length.
1. Adjust the nape strap pad (Figure 2, Item 1) position using nape strap pull-tabs (Figure 2, Item 2). Tighten by
grasping the two tabs, pulling to the back, and then pulling from side-to-side until snug.
2. To loosen the nape, flip buckles (Figure 2, Item 3) towards the center of the nape strap pad. Straps will slide
through buckles easily.
2 3 3 2 1
MS098851A
0016 00-2
TM 1-1680-377-13&P-1 0017 00
OPERATOR INSTRUCTIONS
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
OPERATION UNDER USUAL CONDITIONS FOR HELMET EQUIPMENT
INITIAL SETUP:
Personnel Required WP 0070 00
Crew Member TM 11-5855-263-10
TM 55-1660-247-12
References
0017 00-1
0017 00 TM 1-1680-377-13&P-1
WARNING
0017 00-2
TM 1-1680-377-13&P-1 0017 00
NOTE
The left-hand visor knob is used to raise or lower the outer visor. The right-hand visor knob is
used to raise or lower the inner visor.
To raise and lower visor:
1. Brace your thumb against the visor track, refer to Figure 1.
2. Squeeze the visor knob with your forefinger and slide visor knob down to lower visor, or slide visor knob up to
raise visor.
MS098852A
CAUTION
Ensure that the ANVIS system mounted on your HGU-56/P is working properly in accordance
with TM 11-5855-263-10 prior to using it. Failure to check the ANVIS or to be able to see the low
battery warning light when using the ANVIS may result in a critical loss of equipment use.
Refer to TM 11-5855-263-10 for ANVIS operational procedures.
0017 00-3
0017 00 TM 1-1680-377-13&P-1
MS098853A
2 1
MS098877A
0017 00-4
TM 1-1680-377-13&P-1 0017 00
NOTE
The helmet can be donned or doffed while the MFS is attached to either side and swung open.
The MFS can also be swung open while the helmet is worn, allowing the crewmember to eat or
drink. If the helmet is stowed with the MFS attached, the shield should be secured to the helmet
on both sides.
1. Position the pin (Figure 4, Item 1) on one side of the MFS (Figure 4, Item 3) into the slot (Figure 4, Item 4)
of the striker (Figure 4, Item 5), and flip the latch (Figure 4, Item 2) against the helmet shell. Ensure that the
latch is locked in place.
2. Repeat for the other side.
3. To adjust microphone boom so that it can be placed behind the MFS:
a. Loosen the knurled knob (Figure 4, Item 6) on the SAB.
b. Move the boom forward or back until it can be placed under the recessed area (Figure 4, Item 3) of
the MFS.
c. Tighten the knurled knob.
4. To prevent fogging of visor when wearing the MFS:
WARNING
When using the anti-fogging solution described below, avoid getting the liquid solution into the
eyes. Solution will irritate and may burn the eyes. In case of eye contact, flush with fresh water
for 15 minutes. Contact physician if irritation persists.
a. Apply two drops of Seas Drops anti-fogging solution (WP 0070 00, Item 18a) to the inside surface
of each visor lens.
b. Rub the solution over the entire surface of the lens.
c. Wait 10 seconds, then buff with a microfiber cloth (WP 0070 00, Item 5a) or any soft, dry cloth until
the lens is clear.
1
5 7
3
MS100429A
0017 00-5
0017 00 TM 1-1680-377-13&P-1
REMOVING MFS
1. Flip the latch on one side of the MFS away from the helmet shell, and remove the pin (Figure 4, Item 1) from
the slot.
2. Repeat for the other side.
0017 00-6
TM 1-1680-377-13&P-1 0018 00
OPERATOR INSTRUCTIONS
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
OPERATION UNDER UNUSUAL CONDITIONS
INITIAL SETUP:
NA
UNUSUAL ENVIRONMENT/WEATHER
Not applicable.
CHAPTER 7
OPERATOR
TROUBLESHOOTING PROCEDURES
FOR
HELMET SYSTEM, AIRCREW INTEGRATED
(HGU-56/P)
OPERATOR MAINTENANCE
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
OPERATOR TROUBLESHOOTING
OPERATOR TROUBLESHOOTING
You should perform troubleshooting procedures when you encounter malfunctions of the AIHS helmet.
Following are guidelines for troubleshooting.
Before troubleshooting, ensure that you have performed the daily (pre-flight and post-flight) Preventive Main-
tenance Checks and Services (PMCS). Refer to WP 0022 00, OPERATOR PREVENTIVE MAINTENANCE
CHECKS AND SERVICES (PMCS).
This manual cannot list all possible malfunctions. If you encounter a malfunction not listed below, notify Unit
ALSE Technician.
TROUBLESHOOTING PROCEDURE
0019 00-1
0019 00 TM 1-1680-377-13&P-1
0019 00-2
TM 1-1680-377-13&P-1 0019 00
SYMPTOM
Unable to attach maxillofacial shield.
MALFUNCTION
Hardware is loose,missing, cracked, or broken.
CORRECTIVE ACTION
Report condition to Unit ALSE Technician.
CHAPTER 8
AVIATION UNIT
TROUBLESHOOTING PROCEDURES
FOR
HELMET SYSTEM, AIRCREW INTEGRATED
(HGU-56/P)
TROUBLESHOOTING PROCEDURE
UNIT TROUBLESHOOTING PROCEDURES
SYMPTOM
Unable to raise or lower visor lens.
MALFUNCTION
Defective visor knob.
CORRECTIVE ACTION
Replace defective visor, refer to WP 0039 00.
MALFUNCTION
Defective visor tracks.
CORRECTIVE ACTION
Replace defective visor tracks, refer to WP 0039 00.
MALFUNCTION
Defective visor housing.
CORRECTIVE ACTION
Replace defective visor housing, refer to WP 0039 00.
MALFUNCTION
Defective visor lenses.
CORRECTIVE ACTION
Replace defective lens, refer to WP 0039 00.
0020 00-1
0020 00 TM 1-1680-377-13&P-1
MALFUNCTION
Dust, dirt, and foreign objects in tracks and visor guides
CORRECTIVE ACTION
1. Disassemble visor assembly, refer to WP 0039 00.
2. Using a cleaning cloth dampened with soapy water, clean dust, dirt, and foreign objects from
the tracks and visor guides.
3. Reassemble visor assembly, refer to WP 0039 00.
SYMPTOM
Unable to operate goggles.
MALFUNCTION
Refer to TM 11-5855-263-10.
CORRECTIVE ACTION
Refer to TM 11-5855-263-10.
SYMPTOM
Unable to position AH-l sight.
MALFUNCTION
Refer to TM 9-1270-212-14&P.
CORRECTIVE ACTION
Send operator/wearer with helmet to armament technician for boresighting.
SYMPTOM
Unable to fasten or adjust chin strap.
MALFUNCTION
Defective hardware or webbing.
CORRECTIVE ACTION
Replace retention assembly, refer to WP 0036 00.
SYMPTOM
Unable to adjust nape strap.
MALFUNCTION
Defective hardware or webbing.
CORRECTIVE ACTION
Replace retention assembly, refer to WP 0036 00.
SYMPTOM
Unable to keep microphone in position.
MALFUNCTION
Unable to tighten knurled knob, loose or missing screws.
CORRECTIVE ACTION
Replace SAB, refer to WP 0041 00.
0020 00-2
TM 1-1680-377-13&P-1 0020 00
BLACK
WHITE
3
1 4
BLACK
WHITE
5
MS100437A
0020 00-3
0020 00 TM 1-1680-377-13&P-1
2 5 Good Bad
2 6 Good Bad
5 6 Good Bad
e. The callouts in Figure 2 correspond with the numbers in Table 2 TEMPEST Commu-
nications System.
3
WHITE
4
BLACK & WHITE 1
WHITE
5
MS100436A
0020 00-4
TM 1-1680-377-13&P-1 0020 00
f. Using a multimeter (WP 0063 00, Item 13), perform Test 2 (refer to Step 6.g. or Step
6.h. as appropriate), refer to the appropriate chart for your communication system
(standard or TEMPEST).
(1) If no failure is detected, the communication cord is working. Replace earphone
or microphone as necessary. Proceed to Step 6.i.
(2) If a failure is detected, and you are using the standard communications system,
unscrew the plug cover and check for any loose connections or cold solder joints.
Resolder any defective connections. Proceed to Step 6.i.
(3) If a failure is detected, and you are using the TEMPEST communications system,
replace the communication cord, refer to WP 0011 00, Communication System.
Proceed to Step 6.i.
g. The callouts in Figure 3 correspond with the numbers in Table 3 Test 2 Standard
Communications System.
BLACK
WHITE 3
4 7
1
BLACK 8
9
WHITE
2 10
5 MS100435A
2 or 4 9 Bad Good
5 8 Bad Good
6 10 Bad Good
0020 00-5
0020 00 TM 1-1680-377-13&P-1
h. The callouts in Figure 4 correspond with the numbers in Table 4 Test Points for
TEMPEST Communications System.
WHITE 3
11
8
BLACK & WHITE
1
9
WHITE 10
2
MS100434A
0020 00-6
TM 1-1680-377-13&P-1
CHAPTER 9
OPERATOR MAINTENANCE INSTRUCTIONS
FOR
HELMET SYSTEM, AIRCREW INTEGRATED
(HGU-56/P)
OPERATOR MAINTENANCE
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
WARNING
Do not repair or use any helmet that is damaged beyond the limits set forth in the PMCS charts.
Injury or death may result if you do.
INTRODUCTION
Preventive Maintenance Checks and Services (PMCS) are performed to keep equipment in operating condition.
Checks are used to find, correct, or report problems. PMCS is done every day equipment is operated.
The AIHS PMCS procedure consists of pre-flight and post-flight inspections.
Pre-flight Inspection. Prior to each flight, the user shall inspect the helmet to see that it is in serviceable condition,
reporting any damage to the ALSE technician.
Post-flight Inspection. After each flight, the user shall inform the ALSE technician of any component malfunction
or damage to the helmet.
When performing any PMCS procedure or routine check, observe all safety warnings and cautions.
If your equipment must be in operation at all times, check and service those items that can be checked and serviced
without disturbing operation. Make complete checks and services when equipment can be shut down.
Defects discovered should be corrected as soon as possible. All deficiencies, together with corrective action taken,
should be recorded on forms prescribed for maintenance. See DA PAM 738-751.
PMCS TABLE EXPLANATION
"Item No." Column
This column contains a number for each procedure to be performed. When reporting malfunctions or failures on DA
Form 2408-22, (Equipment Inspection and Maintenance Worksheet).
"Interval" Column
Interval column of your PMCS table tells you when to do a certain check or service. Standard intervals are:
Before - Do before you begin operating equipment.
During - Do while operating equipment.
After - Do after operating equipment.
Periodic - Do once per 180 day interval.
Annual - Do once per 360 6 days interval.
0021 00-1
0021 00 TM 1-1680-377-13&P-1
NOTE
Terms "ready/available" and "mission capable" refer to same status: equipment is on hand and
is able to perform its combat missions (see AR 700-138).
If you find something wrong and you cant fix it yourself, or you are not authorized to, or you do not have tools, test equip-
ment, parts, documentation, or training to fix it yourself, write it on your DA Form 2408-22, inform your supervisor, and
request assistance from next higher level of maintenance.
0021 00-2
TM 1-1680-377-13&P-1 0022 00
OPERATOR MAINTENANCE
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INITIAL SETUP:
Personnel Required WP 0490 00
Crew Member TM 11-5855-263-10
References TM 9-1270-212-14&P
1 B/A Helmet a. Inspect surface for chipped paint with Surface has
Shell penetration of fibers. chipped paint
(Exterior) with penetration of
fibers.
b. Inspect surface for cracks. Surface has cracks.
2. B/A Helmet Inspect visible surface for delaminations larger Visible surface
Shell than a nickel. has delaminations
(Interior) larger than a nickel.
3 B/A Lining, a. Check fit. Loose fit or
Helmet, improperly fitted.
Shock
(EAL/TPL)
b. Check for holes and cracks. EAL has any holes
or compressions,
any gouges deeper
that 1/4-inch any
cracks in front, any
cracks wider than
1/2-inch in rear;
TPL cloth cover is
torn.
0022 00-1
0022 00 TM 1-1680-377-13&P-1
0022 00-2
TM 1-1680-377-13&P-1 0022 00
0022 00-3
0022 00 TM 1-1680-377-13&P-1
0022 00-4
TM 1-1680-377-13&P-1 0023 00
OPERATOR MAINTENANCE
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
CLEANING
INITIAL SETUP:
Materials/Parts Personnel Required
Clean Cloth (WP 0070 00, Item 5) ALSE Technician
Liquid Detergent (WP 0070 00, Item 7)
Double-sided Tape (WP 0070 00, Item 22)
CLEANING
Table 1 lists cleaning tasks for each AIHS assembly.
0023 00-1
0023 00 TM 1-1680-377-13&P-1
CLEANING CONTINUED
NOTE
If the helmet liner
has been involved in
a accident or crash,
helmet liner must be
immediately discarded
and replaced.
0023 00-2
TM 1-1680-377-13&P-1 0023 00
CLEANING CONTINUED
CHAPTER 10
AVIATION UNIT MAINTENANCE INSTRUCTIONS
FOR
HELMET SYSTEM, AIRCREW INTEGRATED
(HGU-56/P)
INITIAL SETUP:
Personnel Required SF 368
ALSE Technician DA PAM 738-751
References
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Combination Square (WP 0063 00, Item 5) Hook and Pile Fastener (WP 0070 00, Item 32)
Ruler (WP 0063 00, Item 21) Personnel Required
Wood Block (WP 0063 00, Item 19) ALSE Technician
Marker (WP 0070 00, Item 27) Operator/Wearer
NOTE
Proper fitting is essential to the functioning of the HGU-56/P, all of its modules, and, conse-
quently, the safety of the Operator/Wearer. Take as much time as necessary to fit the AIHS
precisely. Use extreme care in taking measurements and checking fit.
1. Cut a block of wood (WP 0063 00, Item 19) 1 to 2-inches thick by 3 to 4-inches wide by 8-inches long, refer
to Figure 1.
a. Attach an 8-inch strip of hook and pile fastener to the entire length of the center of one of the 4-inch
wide faces, refer to Figure 1.
b. Attach a 12-inch strip of hook and pile 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 users heads.
HOOK FASTENER
MS098878A
2. Attach the block of wood to the wall at the height of the Operator/Wearers head above the shoulder blades
when the Operator/Wearer is standing.
3. Have the Operator/Wearer stand with back of head against block. Ensure posture and body alignment are
as straight as possible. The Operator/Wearer should hold his or her head in a comfortable position while
focusing on a point directly ahead at eye level.
0025 00-1
0025 00 TM 1-1680-377-13&P-1
WARNING
Proper fitting is essential to the functioning of the HGU-56/P, all of its modules, and, conse-
quently, the safety of the Operator/Wearer. Take as much time as necessary to fit the AIHS
precisely. Use extreme care in taking measurements and checking fit.
4. Using a ruler (WP 0063 00, Item 21), measure a distance 1-1/2-inches above Operator/Wearers pupil, refer
to Figure 2, View A. Using a marker (WP 0070 00, Item 27), make a small mark at this point in the center of
the Operator/Wearers forehead; this is known as the forehead reference point.
5. Using a combination square (WP 0063 00, Item 21), measure from the forehead reference point to the block;
this is the head length, refer to Figure 2, View B. Be careful to just touch the Operator/Wearers skin at the
forehead reference point. Ensure that the square is parallel to the floor and centered on the head.
6
5
4
3
2
1
11/2"
(A)
(B)
MS098879A
0025 00-2
TM 1-1680-377-13&P-1 0025 00
6. Select the correct helmet size based upon head length as shown in Table 1.
INITIAL SETUP:
Tools and Special Tools Personnel Required (cont.)
Operator/Wearer Intercommunications Unit
Operator/Wearer
(WP 0063 00, Item 15)
M-170 Adapter (WP 0063 00, Item 11) References
Materials/Parts WP 0063 00
WP 0065 00
HGU-56/P Helmet Assembly
WP 0028 00
(WP 0065 00, Figure 1 (Sheet 1 of 2), Item 1)
DA Form 2408-22
Personnel Required TM 11-5505-263-10
ALSE Technician TM 55-1650-247-12
FITTING PROCEDURE
NOTE
Proper fitting is essential to the functioning of the HGU-56/P, all of its modules, and, conse-
quently, the safety of the Operator/Wearer. Take as much time as necessary to fit the AIHS
precisely. Use extreme care in taking measurements and checking fit.
NOTE
If optical systems (ANVIS or AH-l) are to be used, check helmet fit with optical systems
attached. Ensure that the helmet is fitted to the forehead reference point.
In preparation for the fitting procedure, operators/wearers with long hair should arrange
their hair so that it lies flat and is completely covered by the helmet. Elevated hair styles
such as buns or French braids will prevent proper fitting of the helmet. The hair must be
worn the same way thereafter.
1. Prior to having operator/wearer don helmet, install thermoplastic liner (TPL) by:
a. Align TPL with front edge of EAL.
b. Place TPL against crown of helmet aligning the holes in TPL (Figure 1, Item 2) with plenum ports
(Figure 1, Item 1) in EAL.
0026 00-1
0026 00 TM 1-1680-377-13&P-1
MS098880A
c. Align TPL with top edge of nap strap pad, so it sits squarely in the helmet.
d. Pull nape strap pad completely down so that keeper tab is taut.
WARNING
Do not remove any plastic layers from the TPL. Removal of plastic layers will result in
decreased helmet stability and may cause injury or death.
Do not add loose plastic layers to the TPL. Adding loose plastic layers will result in
decreased helmet stability and may cause injury or death.
CAUTION
When donning or removing helmet, spread helmet just enough to clear head. Excessive
spreading may damage helmet.
2. Have the Operator/Wearer don the helmet as follows:
a. Hook thumbs in earcups and spread helmet slightly.
b. Position helmet firmly against forehead; rotate helmet rearward and down onto head.
c. Press helmet down firmly with both hands to ensure that helmet is properly positioned on head.
3. Align the edge of the helmet with the forehead reference point.
4. Adjust the earcups so that they cover the Operator/Wearers ears. If earcup pressure is too great without
fitting pads, select the next larger helmet size.
a. Check the earseal compression; earseals should be compressed evenly and to the greatest degree
possible without causing discomfort. Proper earseal compression may be indicated by a visible
ring impression around the ear when the helmet is removed.
0026 00-2
TM 1-1680-377-13&P-1 0026 00
NOTE
The doughnut-shaped pads and the oval pads may be installed whole, cut in half vertically to
adjust forward/rearward earcup tilt, cut in half horizontally to adjust up/down earcup tilt, or cut
in other ways as required to achieve proper earseal compression. Figure 2 shows the more
common ways of trimming the earcup spacer pads. You may have to try various combinations
of pads to achieve proper earseal compression.
5. If the earseals are not sufficiently compressed, add earcup spacer pads as required between the earcup
retaining pad and the helmet shell (NOT between the earcup and the retaining pad).
NOTE
Optional removal of the nape strap foam pad is authorized. Removal of the pad must be
annotated on DA Form 2408-22 (Helmet And Oxygen Mask/Connector Inspection Record).
The nape strap pad should be retained for re-installation upon turn-in of the HGU-56/P helmet.
8. Adjust the nape strap pad for the closest fit possible by tightening or loosening the nape straps. Check the fit
of the nape strap pad with your index finger.
9. Ask the Operator/Wearer to evaluate the fit. If a pressure point exists in the center of the forehead, add
headband fitting pads (Figure 3, Item 1) between the TPL and the EAL to either side of the pressure point to
even the pressure. If any pressure point remains, TPL custom-fitting (WP 0028 00) may be required.
0026 00-3
0026 00 TM 1-1680-377-13&P-1
MS098882A
NOTE
For aircrews operating flying gunships, the AH-1 Cobra boresight must be adjusted by the
armament technician after the initial fitting, every 180 days thereafter (during preventive main-
tenance), and after any maintenance has been performed on the weapons fire control system.
12. If optical systems (ANVIS goggles, AH-1 Cobra sight) are used, place systems in normal operating position
and check for full operational capability in accordance with TM 11-5505-263-10 for ANVIS goggles and TM
55-1650-247-12 for AH-1 Cobra sight.
13. After first flight, recheck and adjust as necessary helmet straps, TPL, and earcups.
0026 00-4
TM 1-1680-377-13&P-1 0027 00
INITIAL SETUP:
Tools and Special Tools Personnel Required
Intercommunications Unit (WP 0063 00, Item 15) ALSE Technician
M-170 Adapter (WP 0063 00, Item 11) Operator/Wearer
Materials/Parts References
Helmet, Flyers, HGU-56/P WP 0026 00
(WP 0065 00, Figure 2, Item 2) WP 0028 00
Mask, Chemical-Biological: M45 WP 0032 00
(WP 0596 00, Figure 1, Item 1) WP 0016 00
Lining, Helmet, Shock, M45 TM 11-5855-263-10
(WP 0065 00, Figure 1 (Sheet 1 of 2), Item 17) TM 9-1270-212-14&P
NOTE
Proper fitting is essential to the functioning of the HGU-56/P, all of its modules, and, conse-
quently, the safety of the Operator/Wearer. Take as much time as necessary to fit the AIHS
precisely. Use extreme care in taking measurements and checking fit.
NOTE
If optical systems, Aviators Night Vision Imaging System (ANVIS) or AH-1 are to be used,
check helmet fit with optical systems attached.
During the fitting, the operator must wear a properly sized, fitted, and adjusted M45 Mask.
Have the operator don the mask before donning the helmet.
In preparation for the fitting procedure, operators with long hair should arrange their hair
so that it lies flat and is completely covered by the helmet. Elevated hair styles such as
buns or French braids will prevent proper fitting of the helmet. The helmet must be worn
the same way thereafter.
1. Remove the standard TPL from the helmet, refer to WP 0032 00.
2. Attach the flat side of the brow pad (Figure 1, Item 1) to the hook and pile fastener at the front of the EAL
(Figure 1, Item 2), ensuring that the bottom edge of the brow pad (Figure 1, Item 1) is flush with the front edge
of the EAL (Figure 1, Item 2).
3. Install the M45 TPL in the helmet, ensuring that:
a. The front edge of the TPL is flush with the top edge of the brow pad.
b. Place TPL against crown of helmet aligning the holes in TPL (Figure 1, Item 3) with plenum ports
(Figure 1, Item 5) in EAL.
c. Align TPL with top edge of nap strap pad, so it sits squarely in the helmet.
d. Ensure the nape strap pad (Figure 1, Item 4) is completely pulled down so that the keeper tab is taut.
0027 00-1
0027 00 TM 1-1680-377-13&P-1
2 3
4
MS098883A
NOTE
If the operator cannot be fitted in accordance with the fitting instructions, contact the United
States Army Aeromedical Research Laboratory (USAARL).
12. If a pressure point exists in the center of the forehead, add headband fitting pads (Figure 2, Item 1) between
the TPL and the EAL to either side-of the pressure point to even the pressure.
0027 00-2
TM 1-1680-377-13&P-1 0027 00
MS098884A
13. Have the operator don the helmet again. If a pressure point remains, custom-fitting (WP 0028 00) may be
required.
14. Repeat Steps 4. through 7. for a final fit check with the mask.
NOTE
15. If optical systems (ANVIS goggles, AH-1 Cobra sight) are used, place the systems in normal operating
position and check for full operational capability in accordance with TM 11-5855-263-10 for ANVIS goggles
and TM 9-1270-212-14&P for the AH-1 Cobra sight.
16. Remove the helmet and the mask.
17. Re-install the brow pad. Ensure the bottom edge of the brow pad is flush with the edge of the EAL.
18. Have the operator don the helmet without the mask. Repeat Steps 4. through 8.
19. After the first flight, recheck and adjust as necessary the helmet straps, the TPL, and the earcups.
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Oven (WP 0063 00, Item 20)
Timer or equivalent (WP 0070 00, Item 35)
Oven Thermometer (WP 0063 00, Item 14)
Ruler (WP 0063 00, Item 21) Personnel Required
Materials/Parts ALSE Technician
Operator/Wearer
Lining, Helmet, Shock, M45
(WP 0065 00, Figure 1 (Sheet 1 of 2), Item 17) References
Tape, Pressure-Sensitive (WP 0070 00, Item 23) WP 0026 00
Gloves, Cotton (WP 0070 00, Item 9) WP 0016 00
WARNING
CAUTION
Do not deform hot, soft TPL by pressing too hard in any one area when positioning liner in
helmet.
When donning or removing helmet, spread helmet just enough to clear head. Excessive
spreading may damage helmet.
If using a non-convection oven to heat the TPL. Ensure that upper burner elements do not
activate during heating, or plastic layers will melt.
Before you place the TPL in the oven, ensure that the cover is attached properly to the
plastic layers (not on backwards).
NOTE
Proper fitting is essential to the functioning of the HGU-56/P, all of its modules, and, conse-
quently, the safety of the operator/wearer. Take as much time as necessary to fit the AIHS
precisely. Use extreme care in taking measurements and checking fit.
NOTE
Do not use a microwave oven; it will not heat plastic layers.
0028 00-1
0028 00 TM 1-1680-377-13&P-1
MS098885A
0028 00-2
TM 1-1680-377-13&P-1 0028 00
MS098886
b. Insert TPL so that the front edge extends approximately 1/4-inch past the front edge of the EAL.
c. While holding nape strap pad keeper taut (Figure 3), position rear of TPL against top edge of nape
strap pad.
MS098887A
0028 00-3
0028 00 TM 1-1680-377-13&P-1
b. Position the helmet firmly against the forehead; rotate the helmet rearward and down onto the head.
NOTE
The TPL top should be compressed as much as possible; this will afford a low center of gravity
and long-lasting comfort.
c. Press the helmet down firmly with both hands to ensure that the helmet is properly positioned on the
head. Maintain as much downward pressure as possible, without causing excessive discomfort,
for 3-5 minutes.
14. Fasten and adjust the chin strap (WP 0016 00).
15. Lower the visors to check centering and nose clearance. If necessary, adjust the visors as follows:
a. Loosen the downstop locking screws (one on each side of the visor) and adjust as necessary.
b. When the desired visor position is attained, tighten the screws.
NOTE
If TPL is not properly fitted, reheat TPL, and repeat custom-fitting procedure.
16. Release pressure on top of head and remove helmet. Ensure that TPL lies smoothly in helmet. Reposition
liner if necessary to align TPL with EAL.
17. Remove pressure-sensitive tape (WP 0070 00, Item 23) from nape strap pad hook and pile fastener.
18. Have Operator/Wearer don helmet. Adjust earcups; tighten nape strap and chin strap.
19. Perform a final fit check. No pressure points should exist; if they do, remove TPL from helmet and repeat
custom-fitting procedure.
20. If the Operator/Wearer does not have a full field of view with ANVIS, remove TPL from helmet and reheat.
21. Re-install TPL in helmet, have operator/wearer don helmet, and press the front of helmet against the head to
compress TPL as much as possible.
22. If fit is still too tight after the TPL has been custom-fitted, select the next larger helmet size.
23. If helmet fits properly, proceed to WP 0026 00.
24. If the Operator/Wearer cannot be fitted per fitting instructions, contact United States Army Aviation Research
Laboratory (USAARL).
0028 00-4
TM 1-1680-377-13&P-1 0029 00
INITIAL SETUP:
Personnel Required WP 0026 00
ALSE Technician and Crew Member WP 0016 00
References
NOTE
Only USAARL may add or remove layers to TPL. Units are NOT authorized to add or remove
layers to TPL.
1. Select proper thickness of Zeta II Liner for crewmember using helmet size, refer to Table 1.
2. Select proper length of Zeta II Liner for crewmember using helmet size, refer to Table 2
0029 00-1
0029 00 TM 1-1680-377-13&P-1
NOTE
Zeta II Liner can be moved slightly forward or aft to accommodate helmet fit.
0029 00-2
TM 1-1680-377-13&P-1 0030 00
WARNING
Do not repair or use any helmet that is damaged beyond the limits set forth in the PMCS charts.
This may result in injury or death to personnel.
Preventive Maintenance Checks and Services (PMCS) are performed to keep equipment in operating condition.
Checks are used to find, correct, or report problems. PMCS is done every day equipment is operated.
The AIHS PMCS procedure consists of pre-flight and post-flight inspections.
Pre-flight Inspection. Prior to each flight, the user shall inspect the helmet to see that it is in serviceable condition,
reporting any damage to the ALSE technician.
Post-flight Inspection. After each flight, the user shall inform the ALSE technician of any component malfunction
or damage to the helmet.
When performing any PMCS procedure or routine check, observe all safety warnings and cautions.
If your equipment must be in operation at all times, check and service those items that can be checked and serviced
without disturbing operation. Make complete checks and services when equipment can be shut down.
Defects discovered should be corrected as soon as possible. All deficiencies, together with corrective action taken,
should be recorded on forms prescribed for maintenance. See DA PAM 738-751.
PMCS TABLE EXPLANATION
"Item No." Column
This column contains a number for each procedure to be performed. When reporting malfunctions or failures on DA
Form 2408-22, (Helmet and Oxygen Mask/Connector Inspection Record).
"Interval" Column
Interval column of your PMCS table tells you when to do a certain check or service. Standard intervals are:
Before - Do before you begin operating equipment.
During - Do while operating equipment.
After - Do after operating equipment.
Periodic - Do once per 180 day interval.
Annual - Do once per 360 6 days interval.
0030 00-1
0030 00 TM 1-1680-377-13&P-1
"Procedure" Column
This column tells you how to perform required checks and services on item to be checked or serviced. Carefully follow
these instructions and perform them in order listed.
"Equipment not Ready/Available If:" Column
This column tells you conditions which will cause equipment to be classified as not ready (red) for readiness reporting.
If there is no entry in this column, this particular item will not cause system as a whole to be declared non-mission ca-
pable if this item is non-mission capable.
NOTE
Terms "ready/available" and "mission capable" refer to same status: equipment is on hand and
is able to perform its combat missions (see AR 700-138).
If you find something wrong and you cant fix it yourself, or you are not authorized to, or you do not have tools, test equip-
ment, parts, documentation, or training to fix it yourself, write it on your DA Form 2408-22, inform your supervisor, and
request assistance from next higher level of maintenance.
0030 00-2
TM 1-1680-377-13&P-1 0031 00
INITIAL SETUP:
Tools and Special Tools References (cont.)
Ruler (WP 0063 00, Item 21)
WP 0032 00
Materials/Parts
WP 0034 00
Marker, Permanent (WP 0070 00, Item 27)
WP 0035 00
Personnel Required WP 0037 00
ALSE Technician WP 0036 00
References WP 0051 00
WP 0023 00 WP 0042 00
WP 0045 00 WP 0041 00
WP 0015 00 WP 0039 00
WP 0056 00 TM 55-1660-247-12
WP 0049 00 WP 0047 00
WP 0040 00 TM 11-5855-263-10
WP 0043 00 TM 9-1270-212-14&P
WP 0058 00 WP 0044 00
1 180 Days Helmet a. Inspect Edge Beading for cuts, tears, or Edge Beading
Shell looseness. has cuts or tears
exceeding 1-inch
or is dangling from
helmet shell. See
WP 0056 00.
b. Inspect the edge for cracks. Edge has any
cracks.
0031 00-1
0031 00 TM 1-1680-377-13&P-1
0031 00-2
TM 1-1680-377-13&P-1 0031 00
2 180 Days Helmet Inspect visible surface for delaminations larger Visible surface
Shell than a nickel. has delaminations
(Interior) larger than a nickel.
See WP 0058 00.
3 180 Days Lining, a. Inspect cloth cover for dirt. Cover is greasy,
Helmet, oily, or dirty. See
Shock WP 0058 00.
(TPL)
b. Inspect plastic layers for adhesion. Layers are
separated.
Replace TPL,
see WP 0032 00.
4 180 Days Zeta II a. Inspect cover fabric for cleanliness and wear. Cover fabric
Liner is dirty and/or
deterioration, worn,
spots, tears, cuts,
broken or skipped
stiches exist (See
WP 0023 00 and
WP 0034 00).
0031 00-3
0031 00 TM 1-1680-377-13&P-1
5 180 Days Energy Inspect liner for breaks and separations. Breaks or
Absorbing separations exist.
Liner See WP 0035 00.
(EAL)
6 180 Days Earcups Inspect earcup for cracks, breaks, or loose/missing Earcup is cracked
hook and pile fastener on back. or broken
(WP 0037 00); hook
and pile fastener is
loose or missing.
7 180 Days Earseals Inspect for cuts, tears, split seams. Cuts or tears
exist; seams are
split, inner foam
is exposed. See
WP 0037 00.
8 180 Days Retention Inspect for broken, loose, or missing hardware; Hardware is
Assembly split seams; fraying; dirt. broken, loose,
or missing; seams
are split; fabric
is frayed, oily,
greasy, or dirty.
See WP 0036 00.
9 180 Days Commu- a. Check earphones for malfunctions. Earphones are
nication malfunctioning.
System See WP 0037 00.
b. Check microphone for malfunctions. Microphone is
malfunctioning.
See WP 0042 00.
c. Check boom assembly for malfunctions. Boom fails to
hold microphone
in place. See
WP 0041 00.
CEP-EQUIPPED HELMETS ONLY
d. Check CEP for malfunctions. CEP is
malfunctioning.
See WP 0051 00.
0031 00-4
TM 1-1680-377-13&P-1 0031 00
e. Check earplug foam tips for dirt or wear. Foam is dirty, worn,
or pulled back from
plastic tubing. See
WP 0023 00.
CEPS-EQUIPPED HELMETS ONLY
f. Check earplug foam tips for dirt and wear. Foam is dirty, worn,
or pulled back from
plastic tubing. See
WP 0023 00.
g. Check battery function. Batteries fail. See
WP 0015 00.
h. Check CEPS On/OFF switch. Switch fails in ON
or OFF position .
i. Check Communications Jack. Not connected
properly.
j. Check Gain/Volume Switch. Switch fails to
function properly.
k. Inspect CEPS harness for frayed wires, or Any wires cut or
loose connection (Helmet interior). frayed.
0031 00-5
0031 00 TM 1-1680-377-13&P-1
15 180 Days Helmet Inspect for dirt, missing hardware, broken Fabric is dirty;
Bag. stitching. hardware is
missing; stitching is
broken.
0031 00-6
TM 1-1680-377-13&P-1 0031 00
17 180 Days Lip Light a. Check attachment to microphone. Lip light insecure.
See WP 0044 00.
b. Check battery function. Batteries fail. See
WP 0044 00.
c. Check switch function. Switch fails in ON or
OFF position. See
WP 0044 00.
INITIAL SETUP:
Materials/Parts Personnel Required
Lining, Helmet, Shock (TPL) ALSE Technician
(WP 0065 00, Figure 2, Item 31)
Lining, Helmet, Shock (TPL),M45
(WP 0065 00, Figure 1 (Sheet 1 of 2), Item 17)
REMOVAL
NOTE
These procedures apply to the TPL and M45 TPL.
Squeeze sides of TPL and remove it from helmet. Refer to Figure 1.
MS098907A
INSTALLATION
Squeezing the sides of the TPL, install TPL in helmet with the rear edge of TPL aligned with top edge of nape strap pad.
Ensure nape hanger strap is taut and hook and pile fasteners are engaged.
INITIAL SETUP:
Materials/Parts ALSE Technician
Brow Pad (WP 0065 00, Figure 2, Item 7) References
Personnel Required EM 0250 Brow Pad Video
REPAIR OR REPLACEMENT
See Brow Pad Video, EM 0250.
1. Remove the brow pad (Figure 1, Item 1) from the Helmet (Figure 1, Item 3).
1
MS098950A
2. Attach flat side of replacement brow pad to hook and pile fasteners at the front of the EAL (Figure 1, Item 2),
ensuring that bottom of brow pad (Figure 1, Item 1) is flush with the front edge of the EAL (Figure 1, Item 2).
INITIAL SETUP:
Personnel Required WP 0032 00
ALSE Technician WP 0029 00
References
REMOVAL
1. If installing a new Zeta II Liner, remove TPL from helmet, refer to WP 0032 00.
2. If installing a replacement Zeta II Liner, remove original Zeta II Liner by squeezing sides of liner and removing
it from helmet.
INSPECTION-ACCEPTANCE AND REJECTION CRITERIA
NOTE
Liner fabric is considered a wear item and requires visual inspection at 180 days.
Inspect the Zeta II Helmet Liner as follows:
1. Remove the Zeta II Liner from the helmet.
2. Inspect Zeta II Liner cover fabric for cleanliness, deterioration, worn, spots, tears, cuts, broken or skipped
stitches.
3. Inspect the foam for deterioration of material.
NOTE
Replace every 3 years from date issued.
4. Ensure Zeta II Liner has been marked with contrasting permanent marker, the date of initial issue.
5. Re-install the Zeta II Liner.
REPAIR OR REPLACEMENT
NOTE
The visco-elastic foam material used in the Zeta II Liner is temperature-sensitive. This material
reacts to body temperature and molds to the users head, forming a custom fit every time the
helmet is worn. In cold weather, the material will feel stiff, but will react to body heat and return
to its optimum temperature of 81 degrees F. in approximately 20 seconds.
NOTE
The Zeta II has a 3 year service life starting when the liner is installed in the helmet. ALSE
technicians should permanently mark on the Zeta II label the month and year that the liner is
installed.
0034 00-1
0034 00 TM 1-1680-377-13&P-1
FRONT
NAPE STRAP
FLAP
MS100129
Figure 1. Bottom (Inside) Attachment of the Hook and Pile Fastener Strip.
2. Grasp the Zeta II Helmet Liner in the middle label side out and place it into the helmet with the front of the liner
toward the front of helmet, starting at the top of the edge roll.
3. Making sure liner is centered in the helmet, press liner to the hook fastener strips at the front. The front edge
of the liner should cover the EAL but not cover the edge roll.
4. Press the Zeta II Helmet Liner into the helmet and then attach the liner to the hook fastener on the nape strap
flap.
0034 00-2
TM 1-1680-377-13&P-1 0035 00
INITIAL SETUP:
Tools and Special Tools Energing Absorbing Liner (EAL)
Screwdriver, Flat-tip (WP 0063 00, Item 27) (WP 0065 00, Figure 2, Item 30)
Spatula (WP 0063 00, Item 2) Personnel Required
Materials/Parts ALSE Technician
NOTE
Before performing this procedure, disengage the chin strap from the D-rings, and loosen nape
strap pad adjustment. This will ease removal of the EAL.
REMOVAL
EAL REMOVAL
1. Detach the earcups from earcup retainer pads by disengaging hook and pile fasteners and passing them
through the retention assembly. Allow earcups to hang outside the helmet by communications cord.
MS098888A
2. Squeeze sides of TPL and remove it from helmet by disengaging the front and rear hook and pile fastener,
refer to Figure 1.
3. Remove the screw, spring washer, and post fastening the retention assembly (Figure 2) to the center rear of
the helmet shell. Retain the screw, washer, and post for reassembly.
0035 00-1
0035 00 TM 1-1680-377-13&P-1
REMOVAL CONTINUED
EAL REMOVAL CONTINUED
REAR RETENTION SCREW
MS098889A
NOTE
5. Use a spatula (Figure 3) to separate the hook and pile fastener attaching the EAL to the helmet shell.
Following the contour of the helmet shell, carefully slide the EAL out through the front of the helmet.
SPATULA
MS038643
0035 00-2
TM 1-1680-377-13&P-1 0035 00
INSTALLATION
EAL INSTALLATION
1. Position the front of the EAL at the rear of the helmet between the nape strap pad assembly and the helmet
shell.
NOTE
Installing the EAL may require some practice.
2. Following the contour of the helmet shell, slide the EAL into the helmet.
3. Attach the hook and pile fastener on the EAL to the hook and pile fastener on the inside of the helmet shell.
Ensure front edge of liner is aligned with front edge of helmet shell.
4. Reattach the nape strap pad to the helmet shell via the screw, washer, and post removed previously.
5. Squeezing the sides of the TPL, re-install it in the helmet with the rear edge of the TPL aligned with the top
edge of the nape strap pad. Ensure that the nape hanger strap is taught and the hook and pile fasteners are
engaged.
6. Reattach the earcups to the earcup retaining pads. Have operator/wearer don helmet and check earcup
position.
INITIAL SETUP:
Tools and Special Tools Personnel Required
Screwdriver, flat-tip (WP 0063 00, Item 27) ALSE Technician
Spatula (WP 0063 00, Item 2) References
Materials/Parts WP 0031 00
Retention Assembly (WP 0065 00, Figure 3, Item 1) WP 0035 00
REMOVAL
NOTE
Ensure that the chin strap is disengaged from the D-rings, and loosen nape strap pad adjust-
ment. This will provide easier access to the helmet for installation.
1. Detach the earcups from earcup retainer pads by disengaging hook and pile fasteners, and passing them
through the retention straps. Allow earcups to hang outside the helmet by communications cord.
2. Squeeze sides of TPL and remove it from helmet by disengaging the front and rear hook and pile fastener,
refer to Figure 1.
MS098892A
3. Remove the screw (Figure 2), spring washer, and post attaching the retention assembly to the center rear of
the helmet shell. Retain the screw, washer, and post for re-installation.
0036 00-1
0036 00 TM 1-1680-377-13&P-1
REMOVAL CONTINUED
REAR RETENTION SCREW
MS098893A
4. Use a Spatula (Figure 3) to separate the hook and pile fastener attaching the EAL to helmet shell.
MS098894A
NOTE
5. Carefully slide the EAL out through the front of helmet, following the contour of helmet shell.
6. Inspect the EAL, refer to WP 0031 00. Replace if necessary following WP 0035 00.
7. Remove retention assembly from the helmet shell by removing two screws (Figure 4, Item 1), washers and
posts on each side of the helmet shell.
0036 00-2
TM 1-1680-377-13&P-1 0036 00
REMOVAL CONTINUED
1
MS098895A
NOTE
Ensure that the holes in the EAL align with the plenum openings for air cooling. In addition, the
square hole should be located to allow access to the retention assembly mounting hardware.
2. Position the front edge of EAL between nape strap pad and helmet shell at the rear of helmet. Following
contour of helmet shell, slide EAL into the helmet until the front edge of the EAL is flush with front edge of the
helmet shell. Ensure that hook and pile fasteners are engaged.
3. Install keeper strap to helmet shell by routing the strap through EAL.
4. Install screw (Figure 2), spring washer, and post attaching the retention assembly to the center rear of the
helmet shell.
5. Squeezing the sides of the TPL, re-install in the helmet with the rear edge of the TPL aligned with top edge of
nape strap pad. Ensure that nape strap is taut and hook and pile fasteners are engaged.
6. Re-install earcups and check fit (WP 0026 00).
INITIAL SETUP:
Tools and Special Tools Personnel Required
Jewelers Screwdriver Set (WP 0063 00, Item 6) ALSE Technician
Materials/Parts References
Earcup Assembly (WP 0065 00, Figure 4) WP 0031 00
REMOVAL
1. Remove the earcup; allow it to hang by the communications cord.
2. Remove the earseal from the earcup by stretching it carefully over the lip of the earcup.
3. Remove the foam receiver retainer from the earcup.
4. Remove the receiver from the receiver retainer.
5. Using a jewelers screwdriver (WP 0063 00, Item 6), loosen (do not remove) the two set screws that secure
the receiver to the communications cord leads.
6. Remove the ear cushion from the earcup.
CAUTION
When removing communications cord leads from the earcup, handle the grommet only; do not
pull on the wires.
7. Carefully remove the grommet from the earcup and pull the communications cord leads through the hole.
8. Inspect all components and replace as necessary, refer to WP 0031 00.
INSTALLATION
1. Insert the communications cord through the hole in the earcup.
2. Insert the grommet into the hole in the earcup. For easier insertion, wet the grommet with plain water if
needed.
3. Insert the communications cord leads into the receiver. Using a jewelers screwdriver (WP 0063 00, Item 6),
tighten the two set screws.
4. Insert the ear cushion lengthwise into the earcup. Center it in the earcup, ensuring that the receiver and the
communications cord leads are accessible.
5. Center the receiver in front of the ear cushion. Insert the receiver retainer into the earcup and center it so that
the receiver is seated in the retainer pocket.
6. Install the earseal on the earcup.
a. Hook one end of the earseal over the lip of the earcup.
b. Carefully stretch the earseal over the remainder of the earcup.
7. Attach the earcup to the earcup retainer pads. Ensure that the hook and pile are firmly engaged.
8. Check earcup position and adjust as necessary.
0037 00-1
0037 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
RECIEVER
RETAINER
EARCUP EAR CUSHION RECEIVER EARSEAL
LEADS
COMMUNICATIONS
CORD
MS038634
0037 00-2
TM 1-1680-377-13&P-1 0038 00
INITIAL SETUP:
Tools and Special Tools Cap-Plug, Protective (WP 0065 00, Figure 2, Item 15)
Screwdriver, Cross-tip (WP 0063 00, Item 28) Personnel Required
Materials/Parts ALSE Technician
REMOVAL
Remove the four screws (Figure 1, Item 1) attaching the cap-plug, protective to the helmet.
INSTALLATION
NOTE
Locking release lever should be in the 3 oclock position as worn.
Install the replacement cap-plug, protective (Figure 1, Item 2) with the four screws removed previously.
MS038642
INITIAL SETUP:
Tools and Special Tools Personnel Required
Jewelers Screwdriver Set (WP 0063 00, Item 6) ALSE Technician
Screwdriver, Cross-tip (WP 0063 00, Item 28) References
Materials/Parts WP 0035 00
Dual Visor Assembly (WP 0065 00, Figure 7) WP 0031 00
REMOVAL
NOTE
Procedures are identical for the opposite side of visor.
NOTE
A nut plate (Figure 1, Item 8) on the underside of the helmet shell holds the posts in place, If the
post threads are stripped, remove EAL as directed in WP 0035 00 and replace the nut plate.
5. Disassemble visors:
a. Slide upper and lower visor apart.
b. Remove retaining rings (Figure 1, Item 3) and bushings (Figure 1, Item 7) from tracks.
c. Repeat Step 5.b. for other side of visor.
6. Inspect components and replace as necessary, refer to WP 0031 00.
INSTALLATION
NOTE
Procedures are identical for the opposite side of visor.
When installing lenses, ensure lens guides are seated in track grooves.
Ensure bushing mates with locking notch in lower track to prevent rotation when installing
or removing thumbscrews.
If EAL was removed, re-install it as directed in WP 0035 00.
1. Insert bushings (Figure 1, Item 7) upward through lower track (Figure 1, Item 6).
2. Place inner visor (Figure 1, Item 9) over lower track.
3. Place middle track (Figure 1, Item 5) over inner visor.
4. Place outer visor on middle track (Figure 1, Item 10).
0039 00-1
0039 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
1
2
11
10 3
9
6
MS098905A
0039 00-2
TM 1-1680-377-13&P-1 0040 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
#1 Screwdriver, Cross-Tip (WP 0063 00, Item 28)
Jewelers Screwdriver Set (WP 0063 00, Item 6) Pencil (WP 0070 00, Item 15)
Materials/Parts Personnel Required
Dual Visor Assembly (WP 0065 00, Figure 7)
ALSE Technician
ANVIS Mount
(WP 0065 00, Figure 1 (Sheet 1 of 2), Item 18) References
Isopropyl Alcohol Pads (WP 0070 00, Item 12) TM 11-5855-263-10
INSTALLATION
1. Remove four thumbscrews that attach visor assembly to helmet; remove visor assembly (Figure 1).
THUMBSCREW
MS098941A
0040 00-1
0040 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
MOUNT
MS098942A
MS098943A
8. Remove the moleskin patch (Figure 4) covering the access cover retaining screw on the inside of the visor
housing.
MOLESKIN PATCH
MS098944A
9. Remove retaining screw securing access cover to housing and remove access cover.
10. Route the cable and the connector under the access cover.
0040 00-2
TM 1-1680-377-13&P-1 0040 00
INSTALLATION CONTINUED
CAUTION
When re-installing the access cover, be careful to install the screws just snugly enough to secure
the cover. Tightening the screws too much may damage the cover.
11. Reattach the access cover and the fairlead, block to the visor housing with the screws (Figure 5, Item 2),
washers, and posts removed in Step 8.
12. Ensure that the red dot (Figure 5, Item 1) on the connector points up and that the knurls (Figure 5, Item 4) on
the connector are seated between the ridges (Figure 5, Item 3) on the block.
4
1
3
MS098945A
13. Install moleskin patches (Figure 6) on the inside of the housing in the pattern shown.
MOLESKIN
PATCHES
14. Align housing over bushings that protrude upward through tracks, and install the thumbscrews through visor
housing and bushings.
15. Position visor housing assembly on helmet, and start four thumbscrews into helmet to attach visor assembly,
refer to Figure 7. After all four thumbscrews are started, tighten them.
0040 00-3
0040 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
THUMBSCREW
MS098947A
16. Attach two 2-inch x 3-inch hook and pile fasteners to the helmet as follows:
PILE
FASTENER
PIECES
MS098948A
NOTE
The only authorized adhesive backed items to be installed on the HGU-56/P helmet are:
The two 2-inch x 3-inch pile fastener pieces for the ANVIS battery pack and weight bag.
The 1-inch x 1 1/2-inch pile fastener for the lip light battery pack will be installed on the left
side of the helmet, centered between the rear ear dome edge and the communication wire
and up 1-inch from helmet edge beading.
No other stickers or self adhesive items are authorized on the HGU-56/P helmet shell or
dual visor assembly housing.
a. Position the two hook and pile fasteners (Figure 8) at the rear of the helmet, and mark the area with
a pencil.
0040 00-4
TM 1-1680-377-13&P-1 0040 00
INSTALLATION CONTINUED
WARNING
Isopropyl alcohol is flammable and toxic to eyes, skin, and respiratory tract. Wear protec-
tive gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well
ventilated areas (or use approved respirator as determined by local safety/industrial hygiene
personnel). Keep away from open flames, sparks or other sources of ignition.
b. Clean the marked area using isopropyl alcohol pads.
c. Remove backing from self-adhesive pile fastener.
d. Install pile fastener on marked area and apply pressure to ensure a good bond.
17. Install the ANVIS goggles (Figure 9), refer to TM 11-5855-263-10.
MS098949A
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Screwdriver, Flat-Tip (WP 0063 00, Item 27) Microphone Boom (WP 0065 00, Figure 2, Item 4)
Screwdriver, Cross-Tip (WP 0063 00, Item 28) Personnel Required
Screwdriver, Jewelers (WP 0063 00, Item 6) ALSE Technician
REMOVAL
1. Unplug microphone cord from communications jack on rear of helmet.
2. Using a cross-tip screwdriver, remove swivel assembly screw (Figure 1, Item 1) and washer (Figure 1, Item
2).
3. Remove the flat washer (Figure 1, Item 3) from boom support washer (Figure 1, Item 9).
4. Using a cross-tip screwdriver, remove screw (Figure 1, Item 6) from knurled knob (Figure 1, Item 7).
5. Unscrew the knurled knob and remove from boom support washer (Figure 1, Item 9).
6. Remove special washer (Figure 1, Item 5) from boom support washer.
7. Remove one of the grooved washers (Figure 1, Item 4) from boom support washer (Figure 1, Item 9).
8. Remove boom (Figure 1, Item 8) and other grooved washer (Figure 1, Item 4).
9. Remove microphone cord from clip attached to boom assembly.
10. Remove thumbscrew from boom and remove microphone from boom.
11. Using a jewelers screwdriver, loosen two set screws and remove microphone from microphone cord.
INSTALLATION
1. Using a jewelers screwdriver, attach microphone to microphone cord and tighten two set screws.
2. Place microphone on boom, install thumbscrew attaching microphone to boom.
3. Using clip attached to boom assembly, attach microphone cord to boom.
4. Attach one of the grooved washers (Figure 1, Item 4) to boom support washer (Figure 1, Item 9).
5. Attach boom (Figure 1, Item 8) and other grooved washer (Figure 1, Item 4).
6. Attach special washer (Figure 1, Item 5) to boom support washer.
7. Screw knurled knob on to boom support washer (Figure 1, Item 9).
8. Using a cross-tip screwdriver, attach screw (Figure 1, Item 6) to knurled knob (Figure 1, Item 7).
9. Attach the flat washer (Figure 1, Item 3) to boom support washer (Figure 1, Item 9).
10. Using a cross-tip screwdriver, attach swivel assembly screw (Figure 1, Item 1) and washer (Figure 1, Item 2).
11. Plug microphone cord into communications jack on rear of helmet.
0041 00-1
0041 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
2 3 4 5
1 6
9 8 7
MS098897A
0041 00-2
TM 1-1680-377-13&P-1 0042 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Screwdriver, Flat-tip (WP 0063 00, Item 27)
Screwdriver, Cross-Tip (WP 0063 00, Item 28) Swivel Assembly, Boom (WP 0065 00, Figure 6)
Spatula (WP 0063 00, Item 2) Personnel Required
Jewelers Screwdriver Set (WP 0063 00, Item 6)
Wrench, Box and Open-end (WP 0063 00, Item 39) ALSE Technician
Materials/Parts References
Earphone (WP 0065 00, Figure 2, Item 25) WP 0037 00
Microphone (WP 0065 00, Figure 2, Item 27) WP 0026 00
Cord Assembly (WP 0065 00, Figure 2, Item 9) WP 0035 00
Cord Assembly (WP 0065 00, Figure 2, Item 13) WP 0032 00
REMOVAL
1. Remove TPL, refer to WP 0032 00.
2. Remove the rear retention screw (Figure 1), spring washer, and post fastening retention assembly to center
of helmet shell. Retain the screw, washer, and post for reassembly.
REAR RETENTION SCREW
MS098893A
NOTE
Removing energy-absorbing liner may require some practice.
0042 00-1
0042 00 TM 1-1680-377-13&P-1
REMOVAL CONTINUED
3
2
MS098901A
Figure 2. Communication Cord Strain Relief Screw and Communication Jack Retaining Plate.
6. Remove the screw (Figure 2, Item 2), washer, and post attaching the communications cord strain relief plate
to the helmet shell.
7. Using a jewelers screwdriver, remove the two screws attaching the communications jack retaining plate
(Figure 2, Item 3) to the rear of the helmet.
8. Untie the communications cord from the communications cord strain relief plate.
9. Remove the communications cord grommet from inside of the helmet through the outside of helmet shell.
10. Remove the entire communications cord from the helmet shell.
REPAIR OR REPLACEMENT
1. Obtain the needed replacement components.
2. Remove the strain relief plate from the communications cord by untying the cord.
3. From the outside of the helmet, pass the entire communications cord though the hole in the rear of the helmet
shell, leaving only the microphone connector with the mounting bracket and the grommet outside the helmet.
4. Insert the grommet into the hole. (If necessary, wet the grommet with plain water to ease insertion.)
5. Install two screws to attach the microphone connector with the jack holder plate to the helmet.
6. Re-tie the strain relief plate (Figure 3, Item 3) to the communications cord (Figure 3, Item 1) in the same
manner in which the cord was originally tied.
4
3 3
6
5
8
MS098904A
0042 00-2
TM 1-1680-377-13&P-1 0042 00
NOTE
When properly tied, the knot (Figure 3, Item 6) should be between the strain relief plate and the
helmet shell (Figure 3, Item 5).
7. Attach the strain relief plate to the helmet shell using a screw (Figure 3, Item 8), post (Figure 3, Item 4), and
spring washer (Figure 3, Item 7).
8. Insert the communications cord leads (Figure 3, Item 3) from the outside of the earcup through the holes.
9. Insert the grommet into the hole in the shell, earphone. For easier insertion, wet the grommet with plain water
if desired.
10. Insert the communications cord leads into the receiver and tighten the set screws.
11. Insert the cushion, ear lengthwise into the shell, earphone. Center it in the shell, ensuring that the receiver
and the communications cord leads are accessible.
12. Center the receiver in front of the cushion, ear. Insert the receiver retainer into the earcup and center it so
that the receiver is seated in the receiver pocket.
13. Repeat Steps 8. through 12. for the other earphone.
14. Plug the microphone cord into the communications cord connector at the rear of the helmet shell.
15. Install helmet EAL, refer to WP 0035 00.
16. Insall helmet TPL, refer to WP 0032 00.
17. Reattach the earcups to the earcup retaining pads. Check earcup position, refer to WP 0026 00.
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Screwdriver, Cross-Tip (WP 0063 00, Item 29) Maxillofacial Shield (WP 0065 00, Figure 11, Item 1)
Drill, Electrical, Portable (WP 0063 00, Item 9) Striker Hardware Kit (WP 0065 00, Figure 11, Item 2)
Drill, Twist, 1/16 (WP 0063 00, Item 32) Latch Hardware Kit (WP 0065 00, Figure 11, Item 3)
Drill, Twist, 1/8 (WP 0063 00, Item 8) White Glue (LP) (WP 0070 00, Item 9a)
Drill, Twist, 3/16 (WP 0063 00, Item 33) 2x4 Block of Wood
Compass with Pencil (WP 0063 00, Item 7)
Personnel Required
Rule, machinists (WP 0063 00, Item 26)
Punch, Center, Solid (WP 0063 00, Item 31) ALSE Technician
Respirator (WP 0063 00, Item 23) References
Scissors, Medical (WP 0063 00, Item 47)
WP 0039 00
Pencil (LP) (WP 0070 00, Item 15)
Goggles, Eye-Protective (WP 0070 00, Item 10)
INSTALLATION
INSTALLING STRIKERS
1. Remove the dual visor assembly from the helmet, refer to WP 0039 00.
HELMET
DIMPLE
ARC
MS098960A
2. Set a compass to the value shown below for your helmet size.
a. Small, XS, XXS: 3-1/8-inches
b. Medium: 3-3/16-inches
c. Large: 3-5/16-inches
0043 00-1
0043 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
d. X-Large: 3-5/16-inches
3. With the compass set to the appropriate value as specified 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, refer to Figure 1.
4. Repeat Step 3. for the other side of the helmet.
5. Set the compass to the value shown below for your helmet.
a. Small, XS, XXS: 2-1/8-inches
b. Medium: 2-1/8-inches
c. Large: 2-3/16 inches
d. X-Large: 2-1/8-inches
6. With the compass set to the appropriate value as specified in Step 5., position the point of the compass below
and against the lower dual visor assembly post on one side of the helmet, and draw an arc to intersect the
first arc, refer to Figure 2.
POST
ARC
MS098961A
0043 00-2
TM 1-1680-377-13&P-1 0043 00
INSTALLATION CONTINUED
WARNING
Wear eye-protective goggles when drilling holes in Steps 9. through 11. to prevent eye
injury.
Use the 2x4 block of wood as described in Steps 9. through 11. to prevent hand injury.
CAUTION
Be careful not to damage any components inside the helmet when performing Steps 9.
through 11.
If the helmet shell is not drilled in the following manner, delamination of the helmet shell
could result, making the helmet unserviceable.
When performing Steps 9. through 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. through 11. to prevent damage to the
helmet shell.
9. At the center punched marks where the two arcs intersect, firmly hold a 2x4 block of wood inside the helmet
shell behind the drilling point. Using a 1/16-inch drill twist, drill a pilot hole. Continue to hold the block in this
manner in Step 10. and Step 11.
10. Using a 1/8-inch drill twist, drill through the pilot hole.
11. Using a 3/16-inch drill twist, finish drilling hole.
12. Repeat Steps 9. through 11. for the other side of helmet.
13. Attach a striker (Figure 3, Item 2) to one side of the helmet by using one screw (Figure 3, Item 1) and a post
(Figure 3, Item 3) through the lower hole of the striker and the drilled hole in the helmet, applying a drop of
white glue to the threads of each screw. Leave the screw just loose enough to allow the striker to rotate.
2
3
1
MS098962A
14. Repeat Step 13. for the other side of the helmet.
15. Reattach the dual visor assembly to the helmet, refer to WP 0039 00.
16. Using the two downstop locking screws (one on each side of visor), adjust visor downstop to lowest position,
refer to Figure 4.
0043 00-3
0043 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
DOWNSTOP
DOWNSTOP LOCKING
LOCKING SCREW
SCREW
MS098963A
17. Attach the MFS (Figure 5, Item 5) to the striker and latch the MFS into place as follows: Position the pin
(Figure 5, Item 1) on the MFS latch (Figure 5, Item 2) into the slot (Figure 5, Item 4) of the striker (Figure 5,
Item 3), and flip the latch against the helmet shell. Ensure that the latch is locked in place.
3 2
MS098964A
0043 00-4
TM 1-1680-377-13&P-1 0043 00
INSTALLATION CONTINUED
NOTE
The helmet can be donned or doffed while the MFS is attached to either side and swung open.
However, if the ML-24 light is attached to the MFS, the MFS should be swung open from the
right side as worn to avoid disconnecting the light. The MFS can also be swung open while the
helmet is worn, allowing the crewmember to eat or drink. If the helmet is stowed with the MFS
attached, the shield should be secured to the helmet on both sides.
18. Swing the MFS to the closed position, and fasten the latch in place as described in Step 17.
19. Lower the inner (clear) visor to the full down position.
NOTE
The MFS must not touch any part of the dual visor housing.
Ensure there is 1/16-inch clearance between the inside surface of the visor and MFS or
visor fogging may occur.
20. Push up or down on the MFS, so that an approximately 1/16-inch clearance exists between the inside surface
of the visor and the top edge beading of the MFS where they overlap. The bottom edge of the visor should
align with the bottom edge of the edge beading on the MFS.
21. With the MFS in position, tighten the two lower striker screws (one on each side of the helmet).
22. Raise the inner visor.
23. Unlatch one side of the MFS and swing the MFS out, ensuring that there is no interference with the dual visor
housing.
24. Re-latch the MFS, and repeat for the other side.
25. Lower inner visor to ensure alignment and clearance of 1/16-inch has be maintained, readjust if necessary.
26. If adjustments were made, raise and lower inner visor to ensure clearance and proper operation. Once this
is complete raise inner visor.
WARNING
Wear eye-protective goggles when drilling holes in Steps 27. through 31. to prevent eye
injury.
Use the 2x4 block of wood as described in Steps 27. through 31. to prevent hand injury.
CAUTION
Be careful not to damage any components inside the helmet when performing Steps 27.
through 31.
If the helmet shell is not drilled in the following manner, delamination of the helmet shell
could result, making the helmet unserviceable.
When performing Steps 27. through 31., 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 27. through 31. to prevent damage to the
helmet shell.
27. With both sides of the MFS latched in place and the two lower striker screws tightened, firmly hold a 2x4 block
of wood inside the helmet shell behind the drilling point. Using a 1/16-inch drill twist, drill a pilot hole through
the upper hole of striker.
0043 00-5
0043 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
28. Using a 1/8-inch drill twist, drill through the pilot hole.
29. Repeat Steps 27. through 28. for the other side of helmet.
CAUTION
When performing following step, ensure that both strikers are rotated out of the way before you
begin drilling. Do not drill through the strikers with the 3/16-inch drill twist.
30. Remove the MFS, loosen the two lower striker screws, and rotate both strikers out of the way to allow access
to the pilot holes drilled in Step 27.
31. Firmly hold a 2x4 block of wood inside the helmet shell behind the drilling point. Using a 3/16-inch drill twist,
drill through both pilot holes (on each side of helmet).
32. Rotate the strikers back to their previous positions. Install the remaining screws (Figure 6, Item 1) and posts
(Figure 6, Item 3) through the upper striker holes and the newly drilled holes to attach the strikers (Figure 6,
Item 2), applying a drop of white glue to the threads of each screw.
33. Tighten all four screws.
2
MS098965A
34. Reattach the MFS, lower the inner visor, and check for proper alignment on the helmet.
35. If the MFS does not align properly, loosen all four screws (with the MFS still attached), realign the MFS as
necessary, and re-tighten the screws.
NOTE
Before donning the helmet in the following step, clean the inside of the helmet to remove all
debris resulting from drilling.
36. Don the helmet and check the operation of the MFS.
37. Adjust the microphone boom as necessary so that it can be placed behind the MFS. To do this, loosen the
knurled knob (Figure 7, Item 1) on the boom swivel, move the boom forward or back until it can be placed into
the recessed space (Figure 7, Item 2) of the MFS, and tighten the knurled knob.
0043 00-6
TM 1-1680-377-13&P-1 0043 00
INSTALLATION CONTINUED
MS098966A
REPAIR OR REPLACEMENT
STRIKER REPLACEMENT
1. Remove screws (Figure 8, Item 1) and posts (Figure 8, Item 3) attaching the striker (Figure 8, Item 2) to be
replaced.
2
3
1
MS100431A
0043 00-7
0043 00 TM 1-1680-377-13&P-1
MS098969A
0043 00-8
TM 1-1680-377-13&P-1 0044 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Pliers, Diagonal Cut (WP 0063 00, Item 24) Strap, Tiedown, Electrical (WP 0070 00, Item 36)
Materials/Parts Personnel Required
Lip Light (WP 0065 00, Figure 12, Item 1) ALSE Technician
NOTE
The Xenon lamp (white light) of the ML-14 lip light is not approved to be used with Night
Vision Goggles Systems (NVGs).
ML-14 Xenon lamp is not a Light Emitting Diode (LED) light source.
Xenon lamp is used when dark adaptation is not necessary and where a strong, bright,
white light is desired.
When using ML-14 lip light in conjunction with NVGs, ensure the two green LEDs light
source is used.
REMOVAL
1. Cut tie down straps securing the lip light power supply wire and remove wire from boom structure.
2. Cut tie down strap securing lip light to microphone assembly.
3. Remove lip light thumbscrew from lip light bracket and remove lip light.
4. Install original microphone thumbscrew (Figure 1) to secure microphone to boom.
INSTALLATION
NOTE
MK-1, Mount Kit mounts the lip light to the aviators microphone. MK-1, Mount Kit is issued with
an assortment of clips to attach the ML-8, ML-14 or ML-18, lip light to boom microphone bracket.
To install the lip light on the HGU-56/P helmet boom microphone bracket, follow the procedures below:
1. Remove original microphone thumbscrew (Figure 1) securing boom microphone.
2. Position lip light so it is positioned along the bottom edge of the microphone with the on-off button facing the
user.
3. Install lip light thumbscrew (Figure 1) (issued with MK-1, Mount Kit) through hole in lip light bracket.
4. Route tie down strap over top of microphone and through the hole on top of the lip light. Tighten tie down
strap and cut excess.
5. Route lip light power supply wire through the boom structure so a minimum of slack exists. Additional tie
down straps may be used to secure the power supply wire or the light assembly to operate the light.
0044 00-1
0044 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
STRAP, TIE DOWN
MICROPHONE
ASSY
THUMBSCREW
MIKE LITE (LIPLIGHT)
MS098981A
0044 00-2
TM 1-1680-377-13&P-1 0045 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Multimeter (WP 0063 00, Item 13) Pad, Isopropyl Alcohol (WP 0070 00, Item 12)
Materials/Parts Personnel Required
Pencil (WP 0070 00, Item 15) ALSE Technician
INSTALLATION
WARNING
Type AA commercial battery labels may be different. Some of the typical labels will contain
short warning statements such as battery may explode or leak if recharged, inserted improperly,
disposed of in fire or mixed with different battery types. Ensure all safety measures are taken
when handling batteries and disposing of batteries. May cause injury or death to personnel.
The battery holder bag, part number BG-AA is constructed of nylon and is attached to the helmet with hook and pile fas-
tener. To install battery pack holder, follow the procedures below.
1. Place a 1 X 2-inch piece of hook and pile fastener at the rear of the helmet for the attachment of battery holder
bag. Mark the area with a pencil.
2. Clean marked area using isopropyl alcohol pads.
3. Remove backing from self-adhesive pile fastener.
NOTE
When installing the lip lights battery pack holder (hook and pile fastener), ensure hook and pile
fastener installation does not interfere with the mounting of the night vision systems low profile
battery pack.
4. Install pile fastener on marked area and apply pressure to ensure a good bond.
NOTE
Prior to installing batteries, use the multimeter or equivalent to test batteries.
5. If batteries indicate less than 80% strength, remove batteries and replace with serviceable batteries.
6. Place two AA batteries into battery holder and connect lead wire from lip light to battery holder.
7. Place battery holder into battery pack holder bag and close.
8. Mount battery pack holder bag to hook and pile fastener on helmet shell.
9. Turn lip light to ON position, perform operational check.
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Screwdriver, Flat-tip (WP 0063 00, Item 27)
#2 Screwdriver, Cross-tip (WP 0063 00, Item 29) Mask-to-Helmet Microphone Cable
#1 Screwdriver, Cross-tip (WP 0063 00, Item 28) (WP 0070 00, Item 10b)
Compass with Pencil (WP 0063 00, Item 7) Snap (WP 0070 00, Item 16d)
Electric Drill (WP 0063 00, Item 9) Screw, Flat Head (2) (WP 0070 00, Item 16c)
5/32 Drill Twist (WP 0063 00, Item 50) Lockwasher (2) (WP 0070 00, Item 10a)
Nut (2) (WP 0070 00, Item 11a)
Materials/Parts
Oxygen Mask Retention Strap (2) Personnel Required
(WP 0070 00, Item 12a) ALSE Technician
INTRODUCTION
This section provides installation instructions for the oxygen mask retention strap assembly. Installation requires minor
modifications of the oxygen mask and the helmet. The installation kit (see Figure 1) contains two oxygen mask reten-
tion straps, a mask-to-helmet microphone cable, and helmet snap hardware.
MASKTOHELMET
MICROPHONE CABLE
OXYGEN MASK
RETENTION STRAPS
MS098985A
0046 00-1
0046 00 TM 1-1680-377-13&P-1
INSTALLATION
FRONT VIEW
SCREWS
SCREWS
2. Attach the replacement straps to the mask using the screws removed in Step 1. Ensure that the pull-the-dot
fastener caps are positioned outward.
3. If a cable exists on the oxygen mask, depress the red release button (see Figure 2) and remove the cable.
4. Install the replacement cable on the mask.
5. Proceed to MODIFYING THE HELMET.
INSTALLATION
3 IN.
2 1/4 IN.
ARC
HOLE TO BE DRILLED
ARC
HEX NUT
SNAP LOCK WASHER
INSTALLATION
SNAP
SCREW
MS098986A
2. On the same side of the helmet, set the compass point at the helmet dimple (located on the eardome). Make
an arc 2-1/4-inches below this point.
0046 00-2
TM 1-1680-377-13&P-1 0046 00
INSTALLATION CONTINUED
MODIFYING THE HELMET CONTINUED
3. Mark the point at which the two arcs intersect. This is the location of the hole to be drilled.
4. Repeat Steps 1. through 3. on the other side of the helmet.
WARNING
CAUTION
Be careful not to damage any components inside the helmet.
If the helmet shell is not drilled in the following manner, delamination of the helmet shell
could result, making the helmet unserviceable.
Hold the drill perpendicular to the helmet shell to prevent damage to the shell and the
energy-absorbing liner.
5. Drill the holes in the marked locations and install the snaps as shown in Figure 3.
6. Proceed to ATTACHING THE MASK TO THE HELMET.
INSTALLATION
CAUTION
Do not release the left-side mask strap during operation. If temporary release is required,
release the right-side strap only.
1. Position the boom and microphone out of the way as shown in Figure 4, or remove the boom and microphone
from the helmet.
MICROPHONE/BOOM
ASSEMBLY
SIDE VIEW
MASK
MICROPHONE
PLUG
MS098987A
2. Attach the left-side mask strap fastener to the left-side helmet snap. The mask strap should be loose.
3. Disconnect the existing microphone plug from the rear of the helmet and plug in the cord attached to the
mask.
0046 00-3
0046 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
ATTACHING THE MASK TO THE HELMET CONTINUED
4. Attach the right-side mask strap to the right-side helmet snap. The mask strap should be loose.
5. Adjust the bottom straps until a uniform seal is obtained.
6. Adjust the top straps as required to complete the facial seal.
0046 00-4
TM 1-1680-377-13&P-1 0047 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Punch, Center, Solid (WP 0063 00, Item 31) Hardware, Mech. Kit (WP 0070 00, Item 25)
File, Hand (WP 0063 00, Item 25) Personnel Required
Screwdriver, Cross-tip (WP 0063 00, Item 28)
ALSE Technician
Screwdriver, Cross-tip (WP 0063 00, Item 27)
Rule, Steel, Machinists (WP 0063 00, Item 26) References
Drill, Electric (WP 0063 00, Item 9) WP 0039 00
Drill, Twist (WP 0063 00, Item 7) WP 0485 00
INSTALLATION
WARNING
Chin strap must be adjusted securely under the Operator/Wearers chin at all times when
the helmet is worn. DO NOT allow the oxygen mask to be placed between the strap and the
Operator/Wearers chin; warn the Operator/Wearer not to fasten the chin strap over the oxygen
mask. Failure to heed this warning will result in a loss of helmet stability and may cause injury to
the Operator/Wearer.
NOTE
Before beginning this procedure, ensure that the retention assembly has been adjusted for
proper helmet fit.
1. Loop two oxygen mask straps through each bayonet assembly. Adjust each strap to its midpoint; this will
allow for tightening and loosening, refer to Figure 1.
0047 00-1
0047 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
TOP RECEIVER HOLE
TO BE MARKED
JAW
RECEIVER
HELMET SHELL
EDGE BEADING
THICKER SIDE
RECEIVER
MOUNTING
BLOCK
MS098938A
CAUTION
Ensure that the receiver mounting block does not rest on top of the helmet shell edge
beading. Failure to comply may result in damage to equipment.
Ensure that the top hole of the jaw assembly is at least 5/8-inch from the edge of the
helmet.
6. Position the left (as worn) jaw receiver assembly and the left receiver mounting block (Figure 1) so that the
left bayonet is correctly positioned and the left receiver mounting block fits the contour of the helmet.
NOTE
Ensure that the thicker side of the tapered receiver mounting block is positioned toward
the helmet shell edge beading.
You may have to adjust the oxygen mask straps several times to achieve the optimum
settings.
0047 00-2
TM 1-1680-377-13&P-1 0047 00
INSTALLATION CONTINUED
11. Center punch the hole marked in Step 8.
WARNING
CAUTION
Before drilling the helmet shell, ensure proper location of receivers. This is important,
because the receivers are only slightly adjustable once they are attached to the helmet.
Failure to comply may result in damage to equipment.
When drilling the helmet shell, hold the drill perpendicular to the shell to prevent damage
to the shell.
12. Place helmet on table. Using an electric drill and a #27 drill twist, drill the hole marked in Step 8. Use a file to
remove any rough edges.
13. Insert the inner 6/32 x 7/16 screw with external lockwasher through the inner hole of the left bayonet receiver
backing plate.
14. Insert screw, lockwasher, and backing plate from inside of helmet shell through hole drilled in Step 12.
NOTE
Ensure that the thicker side of the tapered receiver mounting block is positioned toward
the helmet shell edge beading.
When installing screws, leave the screw loose enough to allow the jaw receiver to pivot so
that proper alignment can be achieved.
15. On the outside of the helmet shell, install the left receiver mounting block, and jaw assembly over the end of
the screw (Figure 2). Finger tighten screw so that receiver can be adjusted as necessary.
SCREWS
LOCK WASHERS
BACKPLATE
HELMET SHELL,
LEFT SIDE AS WORN
(REFERENCE) THICKER SIDE
RECEIVER
MOUNTING
BLOCK
JAW RECEIVER
MS098939A
16. Re-install the earcup and have the Operator/Wearer don the helmet. Insert the left bayonet into the receiver
installed in Step 15. Have the Operator/Wearer hold the mask so that it fits properly.
0047 00-3
0047 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
17. Position the left jaw receiver assembly and the left receiver mounting block until the correct position is
attained. Mark the position of the bottom hole.
18. Remove mask, and have the Operator/Wearer remove the helmet.
19. Pivot the jaw assembly and the receiver mounting block to access the marked hole for drilling.
20. Detach the earcup from the retaining pad, and pull the earcup out of the way. This will prevent damage during
drilling.
21. Center punch the hole marked in Step 17.
WARNING
CAUTION
Before drilling, ensure proper location of receivers. This is important because the re-
ceivers are only slightly adjustable once they are attached to the helmet. Failure to comply
may result in damage to equipment.
When drilling, hold the drill perpendicular to the helmet shell to prevent damage.
22. Place helmet on table. Using an electric drill and a #27 drill twist, drill the hole marked in Step 17. Use a file to
remove any rough edges.
23. Install the outer 6/32 x 9/16 screw, #6 lockwasher, bayonet receiver backplate, left receiver mounting block,
and jaw assembly.
24. Remove the receiver.
25. Remove the inside mounting screw attaching the boom and microphone to the helmet.
WARNING
0047 00-4
TM 1-1680-377-13&P-1 0047 00
INSTALLATION CONTINUED
MS098940A
27. Measure the horizontal position of the holes from the edge beading.
28. Measure the same distance on the opposite side of the helmet shell and mark a corresponding location for
the mounting holes for the other receiver, refer to Figure 3.
29. Detach the earcup from the retaining pad, and pull the earcup out of the way to prevent damage during
drilling.
30. Center punch holes marked in Step 28.
WARNING
CAUTION
Before drilling, ensure proper location of receivers. This is important because the re-
ceivers are only slightly adjustable once they are attached to the helmet. Failure to comply
may result in damage to equipment.
When drilling, hold the drill perpendicular to the helmet shell to prevent damage.
31. Place helmet on table. Using an electric drill and a #27 drill twist, drill the hole marked in Step 28. Use a file to
remove any rough edges.
32. Using the mounting screw removed in Step 25., reattach the boom and microphone to the helmet.
NOTE
Start all four screws before tightening them. Be sure to tighten all four screws.
33. Install two 6/32 x 7/16 screws, two #6 lockwashers, a bayonet receiver backplate, a left receiver mounting
block, and a jaw assembly on each side of the helmet.
34. Install earcups, have the Operator/Wearer don the helmet, and check earcup fit.
0047 00-5
0047 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
35. Position the mask over the Operator/Wearers face. Insert the left bayonet into the left receiver two clicks and
the right bayonet into the right receiver two clicks. Adjust the oxygen mask straps for a secure seal. Attach
microphone cord.
36. Check operation of oxygen mask, refer to WP 0485 00, Checkout Procedure for Mask with Helmet Retention
Devices.
0047 00-6
TM 1-1680-377-13&P-1 0048 00
INITIAL SETUP:
Tools and Special Tools Tools and Special Tools (cont.)
Electric Drill (WP 0063 00, Item 9)
Intercommunication Unit (WP 0063 00, Item 15)
1/8-Inch Drill Twist (WP 0063 00, Item 48)
7/16-Inch Open-End Wrench (WP 0063 00, Item 39)
1/4-Inch Drill Twist (WP 0063 00, Item 49)
3/8-Inch Drill Twist (WP 0063 00, Item 34) Materials/Parts
Jewelers Screwdriver Set (WP 0063 00, Item 6) Solder, Type 40/60 rosin core (WP 0070 00, Item 18)
Long-nose Pliers (WP 0063 00, Item 35) Pencil or Ballpoint Pen (WP 0070 00, Item 15)
Soldering Gun (WP 0063 00, Item 12) Soldering Flux (WP 0070 00, Item 8)
Wire Strippers (WP 0063 00, Item 36) Personnel Required
Razor Knife (WP 0063 00, Item 37)
ALSE Technician
Awl (WP 0063 00, Item 38)
Steel Ruler (WP 0063 00, Item 26) References
Scissors (WP 0063 00, Item 47) WP 0060 00
INSTALLATION
Attaching the CEP Interface Harness (CEP900-104) to Helmet
1. Position the helmet with the right shell eardome down (resting on the table) and the interior facing you, with
the chinstrap unlaced from the D-rings.
2. Remove the right earcup from the helmet and remove the earseal, refer to Figure 1.
RECIEVER
RETAINER
EARCUP EAR CUSHION RECEIVER EARSEAL
LEADS
COMMUNICATIONS
CORD
MS038634
0048 00-1
0048 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
3. Remove the receiver retainer, the receiver, and the filler pad from the earcup, refer to Figure 1.
4. Using a jewelers screwdriver, remove the communications cord leads from the receiver.
5. Remove the communications cord with the grommet from the earcup.
6. Use drill templates from WP 0060 00, TEMPLATE INSTRUCTIONS.
7. Cut the template out in accordance with the procedures on the template page.
8. Position the helmet so that the right side is facing you.
9. Check the size of the helmet.
NOTE
Ensure that the template follows the contour of the helmet shell.
10. Depending upon the helmet size, position one of the four large holes along the top of the template over the
right rear retention screw (located next to the eardome) (Figure 2).
BEND TEMPLATE ALONG EDGE OF EARDOME
PLACE
PROPER
HOLE OVER
RETENTION
SCREW
TEMPLATE
SM
X
XX S
S
XL
PL
AC
H E
RE OL TH
AR E O E P ME LG
RE VE RO D E
TE R T PE
NT HE R S
IO R CR
N IG E
SC HT W
RE
AL
W
IG
N
(IF WIT
PR H C
ES AP
DR EN P
ILL T) LUG
CE
NT
ER
MA
RK
X
AL SM L
IG X L
N
W XX S
ITH S
BO
TT
OM
ED
LG ED
GE
M
E
CAP PLUG OF
HE
LM
ET
SH
EL
L
ONLY ONE
HOLE TO BE
DRILLED
MS100416A
11. Align the curve at the bottom of the template with the helmet shell edge beading. If the helmet has a cap plug,
align the curve on the left side of the template with the cap plug.
12. Depending upon the helmet size, select the drill center mark. Using a pencil or an awl, mark the location of
the hole to be drilled in the shell, through the template hole labeled DRILL CENTER MARK. Ensure that the
mark is located between the bends in the shell along the edge of the eardome and is approximately 1-inch
above the edge of the helmet shell.
0048 00-2
TM 1-1680-377-13&P-1 0048 00
INSTALLATION CONTINUED
WARNING
Wear eye-protective goggles when drilling holes in helmet to prevent eye injury.
When the helmet shell is drilled, the drill twist may penetrate the shell very quickly. To
avoid injury, keep hands away from the inside of the helmet when drilling.
CAUTION
When performing following step, hold the drill perpendicular to the helmet shell to prevent
damage to the shell and the energy-absorbing liner.
Ensure that the earcup, the wires, and the retention assembly inside the helmet shell are
clear from the area where the hole is to be drilled to prevent damage.
If the helmet shell is not drilled in the following manner, delamination of the shell layers
may occur, making the helmet shell unserviceable.
When drilling holes in helmet, paint will flake off from drilling process and degrade helmet.
Refer to WP 0058 00, Hole and Crack Filling for repair.
13. Drill a 1/8-inch hole into the marked location.
14. Drill a 1/4-inch hole into the 1/8-inch hole.
15. Drill a 3/8-inch hole into the 1/4-inch hole.
16. Use a razor knife to remove any frayed helmet fibers resulting from drilling.
17. Slide the large black spacer (Figure 3) over the wires of the interface harness and onto the connector.
SPACER
VIEW A
EARCUP
GROMMET
INTERFACE
HARNESS
CONNECTOR
MS100417A
CAUTION
Do not twist the connector. The interface wire on the back of the connector may break if you do.
NOTE
The earcup grommet may be difficult to pull through the helmet shell.
18. From outside the helmet, insert the black and white wires of the interface harness through the drilled hole so
that the grommet is completely through hole, the head of the connector is against the spacer (Figure 4), and
the spacer is against the outside of the helmet.
0048 00-3
0048 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
VIEW B
(OUTSIDE HELMET)
CONNECTOR
SPACER
MS100418A
19. From inside the helmet, slide the ground lug (Figure 5) over the wires and onto the connector, followed by the
nut. Ensure that the unattached ground wire is pulled through the ground lug and nut (Figure 5).
VIEW C
(INSIDE HELMET)
GROUND LUG
NUT
MS100419A
20. Ensure that the ground lug (Figure 6) is oriented toward the crown of the helmet. Tighten the nut (Figure 5)
using the 7/16-inch open-end wrench. Ensure that the nut is tight enough that the ground lug will not rotate
when pushed.
0048 00-4
TM 1-1680-377-13&P-1 0048 00
INSTALLATION CONTINUED
VIEW D
(INSIDE
HELMET)
WIRE TO BE
SOLDERED
GROUND
LUG
NUT
MS100420A
21. Using long-nose pliers, carefully bend the ground lug to about a 45-degree angle away from the shell to
faciliate soldering.
22. Insert the stripped end of the unconnected ground wire through the small hole at the end of the ground lug.
WARNING
CAUTION
CAUTION
To avoid damage to the earcup shell, ensure that the pilot hole is located properly as specified
in Step 1.
1. Use an awl to make a pilot hole 7/16-inch below (as worn) existing center of the existing hole (Figure 7).
0048 00-5
0048 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
VIEW A
EXISTING HOLE
NONSCALLOPED
SCALLOPED EARCUP
EARCUP
WARNING
Wear eye-protective goggles when drilling holes in earcup to prevent eye injury.
When the earcup is drilled, the drill twist may penetrate the earcup very quickly. To avoid
injury, keep hands away from the inside of the earcup when drilling.
2. Lay the earcup on a flat surface, and drill a 1/4-inch hole (Figure 7) into the pilot hole.
NOTE
When pulling the cord, be careful not to damage the EAL.
3. Carefully pull the part of the communications cord that extends into the right earcup out from behind the
energy-absorbing liner (EAL).
4. Reinsert the communications cord with the grommet back into the previously existing communication cord
hold in the earcup from which it was removed.
NOTE
When pulling the cord, be careful not to damage the EAL.
5. Carefully pull more of the communications cord in to the earcup to allow easier access to the metal tips of the
communications cord leads.
CAUTION
When pulling the cord through the grommet in following step, do not pull on the thin white or
black wires.
6. From outside the earcup, insert the interface harness (Figure 8) into the newly drilled hold and seat the
grommet.
0048 00-6
TM 1-1680-377-13&P-1 0048 00
INSTALLATION CONTINUED
VIEW B COMMUNICATIONS CORD
NONSCALLOPED
SCALLOPED
EARCUP
EARCUP
7. Insert the white wire from the communications cord into the white wire earphone adaptor pin of the interface
harness and tighten screw using a jewelers screwdriver.
8. Insert the black wire from the communications cord into the black wire earphone adaptor pin of the interface
harness and tighten screw using a jewelers screwdriver.
9. Using a jewelers screwdriver, reattach the receiver, refer to Figure 9.
RECEIVER
COMMUNICATION
CORD
INTERFACE
HARNESS
MS100424A
10. From outside the earcup, carefully pull the excess wire from the communications cord and the interface
harness back through the grommets, being careful not to pull the CEP interface cable beyond the point at
which the shrink tubing touches the grommet.
11. Insert the ear cushion, the receiver, and the receiver retainer back into the earcup, and re-install the earseal,
refer to Figure 1.
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Electric Drill (WP 0063 00, Item 9) Black Ink Marker (WP 0070 00, Item 27)
1/8-Inch Drill Bit (WP 0063 00, Item 48) Mixing Stick (WP 0070 00, Item 11)
3/16-Inch Drill Bit (WP 0063 00, Item 49) Electrical Mastic Tape (WP 0070 00, Item 31)
Soldering Gun (WP 0063 00, Item 12) Clear Adhesive/Sealant (RTV) (WP 0070 00, Item 33)
Long-nose Pliers (WP 0063 00, Item 35)
Ruler (WP 0063 00, Item 21) Personnel Required
Mallet, Rawhide (WP 0063 00, Item 22) ALSE Technician
Materials/Parts References
Solder, Type 40/60 Pb/Sn (WP 0070 00, Item 18) WP 0048 00
Pad, Isopropyl Alcohol (WP 0070 00, Item 12) WP 0015 00
Room Temperature Vulcanizing Clear Adhe- ANSI/J-STD-201
sive/Sealant (RTV) (WP 0070 00, Item 33) Equipment Condition
Lip Light Battery Pack (WP 0070 00, Item 29) Use lip light battery pack if no lip light is installed on
Hook and Pile Fastener Tape (WP 0070 00, Item 32) helmet
INSTALLATION
NOTE
One of the interfaces will be installed on the left side of the helmet in a mirror fashion to the right
side installation.
MICROPHONE
CEPS BLACK
MODULE WIRE
GAIN/VOLUME WHITE
SWITCH WIRE
BATTERY QUICKDISCONNECT
BLACK
HOLDER INTERFACE
WIRE
WHITE
WIRE
QUICKDISCONNECT CEPS
MODULE BATTERY
INTERFACE
PACK
MS116082
0049 00-1
0049 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
3. Remove the two forward, retention assembly screws on both sides of the helmet (Figure 2) and store the
harness in the crown of the helmet. Secure the hardware for later installation.
FORWARD RETENTION
ASSEMBLY SCREW
EARPHONE
ASSEMBLY
CHIN STRAP
MS116258
NOTE
MICROPHONE
GAIN/VOLUME
SWITCH
CEPS MODULE
MALE CONNECTOR
QUICKDISCONNECT CEPS
FEMALE CONNECTOR MODULE
MS116255
0049 00-2
TM 1-1680-377-13&P-1 0049 00
INSTALLATION CONTINUED
b. Remove the black mastic tape from the center post (Figure 4) of the interface connector.
WARNING
NOTE
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
c. Solder the ring terminal on the white wire (Figure 4) to the interface connector center post.
WHITE
RING WIRE
TERMINAL
CENTER
POST
SOLDERING
GUN
BLACK WIRE
INTERFACE
CONNECTOR
MS116257
WARNING
NOTE
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
d. Solder the black wire (Figure 5) of the CEPS quick-disconnect to the ground lug (Figure 5) of the
CEP interface.
0049 00-3
0049 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
HOOK FASTENER
BLACK WIRE
GROUND
LUG
WHITE WIRE
CEPS MODULE
MALE CONNECTOR
MS038812
NOTE
Repeat the following procedures on the opposite side of the helmet.
WARNING
Isopropyl alcohol is flammable and toxic to eyes, skin, and respiratory tract. Wear protec-
tive gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well
ventilated areas (or use approved respirator as determined by local safety/industrial hygiene
personnel). Keep away from open flames, sparks or other sources of ignition.
c. Clean inner surface of helmet around edge bead and EAL with alcohol and let surface dry.
d. Attach hook fastener (Figure 6) to helmet shell in the area above interface connector and EAL.
0049 00-4
TM 1-1680-377-13&P-1 0049 00
INSTALLATION CONTINUED
EDGE OF EAL
HOOK
FASTENER
CLEAR
ADHESIVE (RTV)
MS116081
NOTE
The circuit board with the volume control wire (gain switch) will be installed on the right side.
e. Attach the CEPS module (Figure 7) to the hook fastener with microphone lead (Figure 7) directed
toward the crown of the helmet.
EDGE OF EAL
CEPS MODULE
MALE CONNECTOR
CEPS MODULE
QUICKDISCONNECT
FEMALE CONNECTOR
MICROPHONE
LEAD
RIGHT EDGE
OF HELMET
MS116085
0049 00-5
0049 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
f. Insert quick-disconnect female connector into CEPS module male connector (Figure 7).
NOTE
The battery pack and On/Off switch are located on the rear left side of helmet.
The battery pack will replace the battery pack used by the lip light.
If lip light is already installed, it can be plugged on top of the CEPS battery pack.
If no lip light is installed, user will need the battery holder to secure CEPS battery pack.
6. On the backside of helmet, install a square of loop fastener tape to the left of the communications jack for
Battery Holder and attach Battery Holder (Figure 8) to loop fastener.
COMMUNICATIONS
JACK
BATTERY
HOLDER ANVIS
CEPS ON/OFF
SWITCH PILE
FASTENER
MICROPHONE
CORD
MS116093
NOTE
Repeat the following steps on opposite side of helmet.
0049 00-6
TM 1-1680-377-13&P-1 0049 00
INSTALLATION CONTINUED
EARDOME
DIMPLE
FORWARD
SCREW
MASKING
TAPE
MS116078
b. Place a line that connects the forward screw and eardome dimple and make a drill mark 1.5-inches
(Figure 10) from the eardome dimple.
EARDOME
DIMPLE
FORWARD
SCREW
DRILL MARK
1.5"
MS116077
Figure 10. Measuring and Marking Drill Location for Microphone Hole.
0049 00-7
0049 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
WARNING
Wear eye-protective goggles when drilling holes in helmet to prevent eye injury.
When the helmet shell is drilled, the drill twist may penetrate the shell very quickly. To
avoid injury, keep hands away from the inside of the helmet when drilling.
CAUTION
Hold the drill perpendicular to the helmet shell to prevent damage to the shell.
Ensure that the earcup, the wires, and the retention assembly inside the helmet shell are
clear from the area where the hole is to be drilled to prevent damage.
c. Drill a 1/8-inch hole through helmet shell.
NOTE
Repeat the following steps on opposite side of helmet.
WARNING
Isopropyl alcohol is flammable and toxic to eyes, skin, and respiratory tract. Wear protective
gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in wellventilated
areas (or use approved respirator as determined by local safety/industrial hygiene personnel).
Keep away from open flames, sparks or other sources of ignition.
b. Clean the inner and outer surface of helmet in the area around the 1/8-inch microphone hole with
Pad, Isopropyl Alcohol and let the surface dry.
c. Position the microphone with the microphone nozzle in the hole (Figure 11). The end opposite the
hole should be positioned at a 45 degree angle upwards toward the EAL edge with the wire posi-
tioned along the edge of the EAL. Double check the microphone position, centering the microphone
nozzle on the exterior of the helmet shell.
EDGE OF EAL
INTERIOR OF HELMET
MICROPHONE
NOZZLE
MS116083
0049 00-8
TM 1-1680-377-13&P-1 0049 00
INSTALLATION CONTINUED
d. Remove tape backing from microphone and place microphone nozzle (Figure 12) in microphone
hole, using push pin for alignment.
MS116084
e. Hold the microphone in place for approximately 30 seconds to insure tape bonds with the helmet
shell interior surface.
f. When both microphones have been placed, remove the adhesive backing on the microphone
covers provided, center and place them over the two microphone ports on the exterior of the helmet
shell.
g. Hold them in place momentarily to let the adhesive set.
NOTE
If nasal cannula is installed, go to Step 13.
BLACK INK
MARKER
GAIN SWITCH
BACK PLATE
MS038814A
0049 00-9
0049 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
WARNING
Wear eye-protective goggles when drilling holes in helmet to prevent eye injury.
When the helmet shell is drilled, the drill twist may penetrate the shell very quickly. To
avoid injury, keep hands away from the inside of the helmet when drilling.
CAUTION
Hold the drill perpendicular to the helmet shell to prevent damage to the shell.
Ensure that the earcup, the wires, and the retention assembly inside the helmet shell are
clear from the area where the hole is to be drilled to prevent damage.
b. Using a 3/16-inch Drill Twist, drill holes at marked location.
c. Place gain/volume switch cable in backplate notch and secure with two screws to interior of helmet
shell, refer to Figure 14.
RIGHT INNER
SIDE OF HELMET
GAIN SWITCH
BACK PLATE
MS038813
0049 00-10
TM 1-1680-377-13&P-1 0049 00
INSTALLATION CONTINUED
NOTE
In order to interface the nasal cannula mounting clip and the CEPS Gain/Volume Switch requires
removal of the threaded inserts from the nasal cannula mounting clip.
13. If the nasal cannula mounting clip for the Portable Helicopter Oxygen Delivery System (PHODS) (Figure 15)
is installed, proceed as follows:
PHODS
MS038669
a. Remove nasal cannula mounting clip (Figure 16) from helmet, retain screws to re-install.
RIGHT
INNER SIDE
OF HELMET
NASAL CANNULA
MOUNTING CLIP MS116089
b. Using the removed screws, from the mounting surface side, thread approximately 4 threads into
the threaded insert of the nasal cannula mounting clip.
c. Place the edge of the nasal cannula mounting clip against a block of wood.
d. Using a mallet, tap the head of the screw to remove insert.
e. Separate the threaded insert from screw.
f. Repeat Steps 13.b. through 13.e., for the second insert.
g. Install gain/volume switch and secure with two screws, retained from nasal cannula mounting clip,
on inside of helmet.
0049 00-11
0049 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
14. Install the two forward, retention assembly screws on both sides of the helmet.
15. Perform operational check, refer to WP 0015 00.
16. Remove adhesive backing and secure Quick-Disconnect Male/Female Connectors to CEPS module.
17. Place RTV clear adhesive/sealant or electrical mastic tape on soldered portion of center post, ensuring the
exposed solder is completely covered.
0049 00-12
TM 1-1680-377-13&P-1 0050 00
INITIAL SETUP:
Tools and Special Tools Black Ink Marker (WP 0070 00, Item 27)
Electric Drill (WP 0063 00, Item 9) Personnel Required
3/16-Inch Drill Bit (WP 0063 00, Item 49) ALSE Technician
Materials/Parts
INSTALLATION
1. Using the nasal cannula mounting clip, mark the drill hole locations about midway on the lower edge beading
of the right eardome (Figure 1).
TO MARK HOLE
NASAL CANNULA POSITION
MOUNTING CLIP
EDGE BEADING
MS040355
WARNING
Wear eye-protective goggles when drilling holes in helmet to prevent eye injury.
When the helmet shell is drilled, the drill twist may penetrate the shell very quickly. To
avoid injury, keep hands away from the inside of the helmet when drilling.
CAUTION
Hold the drill perpendicular to the helmet shell to prevent damage to the shell.
Ensure that the earcup, the wires, and the retention assembly inside the helmet shell are
clear from the area where the hole is to be drilled to prevent damage.
2. Using a 3/16-inch Drill Twist, drill holes at marked location.
3. Secure nasal cannula mounting clip with two screws to interior of helmet shell, refer to Figure 2.
0050 00-1
0050 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
RIGHT
INNER SIDE
OF HELMET
NASAL CANNULA
MOUNTING CLIP MS116089
0050 00-2
TM 1-1680-377-13&P-1 0051 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Screwdriver, Flat-tip (WP 0063 00, Item 27)
Screwdriver, Cross-tip (WP 0063 00, Item 28) Cord Assembly (WP 0065 00, Figure 2, Item 9)
Spatula (WP 0063 00, Item 2) Swivel Assembly, Boom (WP 0065 00, Figure 6)
Jewelers Screwdriver Set (WP 0063 00, Item 6) Personnel Required
Soldering Gun (WP 0063 00, Item 12)
Pliers, Long-nose (WP 0063 00, Item 35) ALSE Technician
Wrench, Box and Open-end (WP 0063 00, Item 39) References
Materials/Parts WP 0035 00
Solder, type 40/60 rosin core (WP 0070 00, Item 18) WP 0037 00
Earphone (WP 0065 00, Figure 2, Item 25) ANSI/J-STD-201
Microphone (WP 0065 00, Figure 2, Item 27) WP 0032 00
REMOVAL
1. Remove TPL, refer to WP 0032 00.
2. Remove the rear retention screw (Figure 2), spring washer, and post fastening the retention assembly to the
center rear of the helmet shell. Retain the screw, washer, and post for reassembly.
MS098893A
0051 00-1
0051 00 TM 1-1680-377-13&P-1
REMOVAL CONTINUED
NOTE
Removing EAL may require some practice.
2
MS098901A
Figure 2. Communication Cord Strain Relief Screw and Communication Jack Retaining Plate.
8. Untie the communications cord from the communications cord strain relief plate.
WARNING
CAUTION
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
9. Unsolder the CEP interface harness leads, separating the interface harness from the receiver leads.
0051 00-2
TM 1-1680-377-13&P-1 0051 00
REMOVAL CONTINUED
CAUTION
When removing communications cord leads from the earcup shell, handle the grommet only;
do not pull on the wires.
10. Remove the CEP interface harness leads from each earcup shell, handling the grommet only.
11. Remove the communications cord grommet from each earcup shell.
12. Carefully pull the communications cord leads through the hole in each earcup shell.
WARNING
CAUTION
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
13. Unsolder and remove the CEP ground wire (Figure 3, Item 2) from the ground lug (Figure 3, Item 1) on the
inside of the helmet.
MS038641
0051 00-3
0051 00 TM 1-1680-377-13&P-1
REMOVAL CONTINUED
4
2
1
OUTSIDE
HELMET
5
MS038639
Figure 4. Connector.
15. From the outside of the helmet, pull the connector (Figure 4, Item 1) and interface harness with the spacer
(Figure 4, Item 2) from the helmet. Be sure to pass the ground wire (Figure 4, Item 5) through the hex nut and
ground lug.
16. Remove the communications cord grommet from the rear of the helmet through the outside of the helmet
shell.
17. Pull the entire communications cord from the grommet hole.
REPAIR OR REPLACEMENT
1. Obtain the needed replacement components.
2. Remove the strain relief plate from the communications cord by untying the cord.
3. From the outside of the helmet, pass the entire communications cord though the hole in the rear of the helmet
shell, leaving only the microphone connector with the mounting bracket and the grommet outside the helmet.
4. Insert the grommet into the hole. (If necessary, wet the grommet with plain water to ease insertion.)
5. Install two screws to attach the microphone connector with the jack holder plate to the helmet.
6. Re-tie the strain relief plate (Figure 5, Item 3) to the communications cord (Figure 5, Item 1) in the same
manner in which the cord was originally tied.
0051 00-4
TM 1-1680-377-13&P-1 0051 00
3 3
4
5
MS116091
NOTE
When properly tied, the knot (Figure 5, Item 4) should be between the strain relief plate and the
helmet shell (Figure 5, Item 5).
7. Attach the strain relief plate to the helmet shell using a screw (Figure 5, Item 7), post (Figure 5, Item 2), and
spring washer (Figure 5, Item 6).
8. Slide the spacer (Figure 4, Item 2) over the communications cord and the CEP interface harness and place it
near the connector (Figure 4, Item 1).
a. Insert the CEP interface harness from the outside of the helmet through the hole from which it was
previously removed.
b. Insert the connector into the hole, ensuring that the spacer is against the helmet and the connector
is against the spacer.
9. From inside the helmet, slide the ground lug (Figure 4, Item 3) over the wires and onto the connector, followed
by the nut (Figure 4, Item 4). Ensure that the unattached ground wire is pulled through the ground lug and nut
as shown in Figure 4.
10. Ensure that the ground lug is oriented toward the crown of the helmet as shown in Figure 4. Tighten the nut
using the 7/16-inch open-end wrench. Ensure that the nut is tight enough that the ground lug will not rotate
when pushed.
11. Using long-nose pliers, carefully bend the ground lug to about a 45 angle from the shell so that it reaches the
unconnected ground wire.
a. Insert the stripped end of the unconnected ground wire (Figure 4, Item 5) through the small hole at
the end of the ground lug (Figure 4, Item 3).
b. Wrap the exposed part of the wire once around the end of the ground lug.
0051 00-5
0051 00 TM 1-1680-377-13&P-1
WARNING
CAUTION
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
c. Solder the wire.
d. Bend the ground lug flush with the inside surface of the helmet shell.
WHITE
WIRE
COMMUNICATIONS CORD
ATTACHMENT
DETAIL BLACK
WIRE
GROMMET
INTERFACE HARNESS
MS116092
12. From outside the earcup, insert the interface harness into the hole from which it was previously removed and
seat the grommet. (See Figure 6.)
13. Carefully pull additional wire through grommet into the earcup to make soldering connections easier.
14. Using long-nosed pliers, bend the stripped end of the interface harness into a hook and fit the hook around
the exposed black wire of the communications cord lead as shown in Figure 6 attachment detail.
0051 00-6
TM 1-1680-377-13&P-1 0051 00
WARNING
CAUTION
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
NOTE
Use only rosin core solder when soldering the wires.
15. Solder the hook and the exposed black wire to form a single function.
16. Repeat Steps 12. through 15. to connect the white lead of the interface harness to the white wire of the
communications cord.
NOTE
The receiver is not polarized. In the following step, the white and black wires can be attached to
the receiver either way.
17. Insert the communications cord and leads into the receiver and tighten the set screws.
18. Insert the ear cushion lengthwise into earphone shell and center ear cushion in shell.
19. Ensure receiver and communications cord leads are accessible.
20. Center the receiver in front of the ear cushion. Insert the receiver retainer into the earcup and center it so that
the receiver is seated in the receiver pocket.
21. Repeat Steps 12. through 20. for the other earphone.
22. Plug the microphone cord into the communications cord connector at the rear of the helmet shell.
23. Install EAL, refer to WP 0035 00.
24. Install TPL, refer to WP 0032 00.
INITIAL SETUP:
Tools and Special Tools ALSE Technician
Screwdriver, Flat-tip (WP 0063 00, Item 27) References
Materials/Parts WP 0026 00
Standard Dual Visor Assembly WP 0035 00
(WP 0065 00, Figure 7) WP 0032 00
Personnel Required
REMOVAL
NOTE
Ensure that the chin strap is disengaged from the D-rings. This will provide easier access to the
helmet for installation.
MS098927A
0052 00-1
0052 00 TM 1-1680-377-13&P-1
REMOVAL CONTINUED
5. Loosen the four thumbscrews (Figure 1, Item 2) attaching the Cobra visor housing to the helmet shell out of
the nut plates.
NOTE
The Cobra module is accountable as MTOE and will remain with the unit.
6. Remove the Cobra visor assembly (including visor housing, thumbscrews, visor lenses, and track assem-
blies) from the helmet.
INSTALLATION
1. Install the screw (Figure 1, Item 1), spring washer, and post (without the leg attached) into the hole in helmet
shell.
2. Align the standard dual visor assembly on the helmet shell.
NOTE
DO NOT tighten any of the screws until all four have been started.
THUMBSCREW
MS100427A
NOTE
Ensure that the holes in the EAL align with the plenum openings for air cooling. In addition, the
square hole should be located to allow access to the retention assembly mounting hardware.
0052 00-2
TM 1-1680-377-13&P-1 0053 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Knife, Pocket (WP 0063 00, Item 30) AH-1 Cobra Sight
Screwdriver, Cross-Tip, #2 (WP 0063 00, Item 29) Cobra Dual Visor Module (WP 0065 00, Figure 8)
Screwdriver, Cross-Tip, #1 (WP 0063 00, Item 28) Insulation Sleeving (WP 0070 00, Item 17)
Screwdriver, Flat-tip (WP 0063 00, Item 27) Tin alloy Solder (WP 0070 00, Item 18)
Punch, Center, Solid (WP 0063 00, Item 31) Personnel Required
Pliers, Diagonal Cutting (WP 0063 00, Item 24)
ALSE Technician
Gun-type Electric Heater (WP 0063 00, Item 10)
Soldering Gun (WP 0063 00, Item 12) References
Metal Cutting Hand Saw (WP 0063 00, Item 16) TM 9-1270-212-14&P
Drill, Electric (WP 0063 00, Item 9) ANSI/J-STD-201
Spatula (WP 0063 00, Item 2) WP 0035 00
#43 Tap Drill (WP 0063 00, Item 4) WP 0032 00
#4-40 Tap (WP 0063 00, Item 3)
REMOVAL
MS040264
Figure 1. Connector.
0053 00-1
0053 00 TM 1-1680-377-13&P-1
REMOVAL CONTINUED
COBRA DUAL VISOR MODULE CONTINUED
WARNING
CAUTION
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
2. Using soldering gun, unsolder the eight conductors attached to the connector terminals.
CAUTION
Be careful not to cut the cable if you have to cut the shrinkable electrical insulation sleeving
away from the connector.
3. Slide the strain relief electrical insulation sleeving from the connector wires.
CAUTION
Be careful not to cut the AH-1 Cobra cable when cutting through the glue attaching the cable to
the housing.
4. Cut through the adhesive attaching the cable (Figure 2, Item 1) to the inside of the visor housing.
5. Pull the cable through the leg (Figure 2, Item 2) of the visor housing.
MS098908A
6. Remove the screw and washer from the end of the sight assembly shaft (Figure 3). Pinch the locking spring
holding the sight shaft and remove the sight shaft from the sight assembly.
7. Remove the three screws and washers that attach the magnetic coupler (Figure 6, Item 1) to the visor
housing.
0053 00-2
TM 1-1680-377-13&P-1 0053 00
REMOVAL CONTINUED
COBRA DUAL VISOR MODULE CONTINUED
WARNING
CAUTION
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
8. Using soldering gun, de-solder the two wires on the-magnetic coupler.
9. Pull the wires carefully through the holes in the front of the visor housing, thereby removing the existing sight
completely.
10. Remove the three screws on the sight assembly.
11. Remove the screw and spring washer attaching the tapered tensioning disk from the back of the sight
assembly, and attach the flat tensioning disk.
12. Remove V-2 mount from existing Cobra housing, refer to TM 9-1270-212-14&P.
ASSEMBLY
NOTE
In order for the AH-1 Cobra sight to function properly on the AIHS helmet, the sight shaft may
have to be modified by A QUALIFIED SUPPORT UNIT.
1. Measure the shaft length. If it is 3-11/16-inches, it has already been modified; proceed to Step 3. Otherwise,
refer to Figure 3 and perform Steps 1.a. through 1.e. as follows:
11"
16
3
MS098909A
0053 00-3
0053 00 TM 1-1680-377-13&P-1
ASSEMBLY CONTINUED
COBRA DUAL VISOR MODULE ASSEMBLY CONTINUED
b. Use a metal-cutting hand saw to cut the top end of the shaft (the end from which the screw was
removed) so that the shaft measures 3-11/16-inch after cutting.
c. Using a center punch, mark the center of the shortened end.
d. Use a #43 tap drill to drill a hole to a depth of 5/16-inch.
e. Using a #4-40 tap, thread the hole.
2. Remove four thumbscrews from visor housing.
3. Separate the tracks from Cobra dual visor housing.
4. Insert the end of the AH-1 Cobra cable through the smaller hole in the front of the visor housing.
NOTE
Before installing the AH-1 Cobra sight, the tensioning disk on the back of the sight may need to
be loosened. This ensures proper alignment of the sight with the mounting pattern of the visor
housing.
5. Attach the AH-1 Cobra sight (Figure 4, Item 1) to the housing with three screws, lockwashers, and washers.
1
MS098910A
6. Route the wires along the underside of the visor housing and secure them with electrical tape. See Figure 5.
WIRES
MS098911A
0053 00-4
TM 1-1680-377-13&P-1 0053 00
ASSEMBLY CONTINUED
COBRA DUAL VISOR MODULE ASSEMBLY CONTINUED
7. Insert the orange wire through the forward hole and the violet wire through the rear hole in the magnetic
coupler mounting area.
WARNING
CAUTION
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
NOTE
When soldering the conductor wires, ensure that magnetic coupler is oriented with solder
terminals to right of mounting area (over the feed through holes).
Conductor wires need to be long enough to be routed and installed properly after wires
have been cut and stripped.
Do not install the tapered block that you previously removed with the coupler; this block
will no longer be used.
8. Using soldering gun, soldering flux, and tin alloy solder, solder the two conductor wires to the magnetic
coupler terminals as follows:
a. Connect the orange wire to the terminal closest to the front of the visor housing.
b. Connect the violet wire to the terminal closest to the rear of the visor housing.
9. Attach the magnetic coupler (Figure 6, Item 1) to the visor housing with three screws, star lockwashers, and
flat washers.
1
MS098912A
0053 00-5
0053 00 TM 1-1680-377-13&P-1
ASSEMBLY CONTINUED
COBRA DUAL VISOR MODULE ASSEMBLY CONTINUED
WARNING
On direct contact, silicone adhesive type I causes eye and skin irritation. In case of skin contact
wash with soap and water. In case of eye contact, flush with water for 15 minutes. Use in a well
ventilated area.
NOTE
If necessary, use a small amount of silicone adhesive type I in this area to ensure that the cable
will be positioned properly during visor housing installation. Ensure that the adhesive cures
properly before re-installing the housing.
10. Insert the end of the cable from inside the visor housing through the hole in the housing leg (Figure 6, Item 2).
Carefully pull the cable through the hole.
WARNING
There is a danger of a burn injury when working with a gun-type electrical heater.
11. Using a gun-type electrical heater, install a 1-inch piece of shrinkable electrical insulation sleeving on the
cable and against the visor housing leg for strain relief.
NOTE
In some cases, you may have to install shrinkable electrical insulation sleeving of a larger
diameter over the 1-inch shrinkable electrical insulation sleeving installed on the cable.
12. Using a gun-type electrical heater, install the larger shrinkable electrical insulation sleeving for the connector
clamp onto the cable.
13. Slide the piece of tubing (Figure 1) removed in REMOVAL, Step 3. onto the cable.
14. Install the connector plug housing onto the cable.
NOTE
15. If necessary, cut, strip, and tin the eight conductor leads.
0053 00-6
TM 1-1680-377-13&P-1 0053 00
ASSEMBLY CONTINUED
COBRA DUAL VISOR MODULE ASSEMBLY CONTINUED
WARNING
CAUTION
Ensure that all soldering/unsoldering procedures are performed by trained personnel, refer to
ANSI/J-STD-201.
16. Using a soldering gun, soldering flux, and tin alloy solder, solder the conductor leads to the connector terminal
in the following pattern, refer to Figure 7:
Color Terminator
White 1
Brown 2
Blue 3
Black 4
Violet 5
Orange 6
Red 7
Yellow 8
BLUE VIOLET
RED
1 3 5 7
WHITE
YELLOW
BROWN
6 8
2 4
ORANGE
BLACK
MS098913A
17. Slide the connector housing over the connector body and install the housing pin.
18. Tighten the two screws in the cable connector clamp.
INSTALLATION
ANVIS Mount Installation
1. Position the mount (Figure 8, Item 2) with its holes aligned over the holes in the housing.
0053 00-7
0053 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
1
MS098914A
MS098915A
4. Attach the cable clamp (Figure 9, Item 2) with the screw and post (Figure 9, Item 3).
5. Install moleskin patches (Figure 10) to cover the screws on the inside of the visor housing.
MS098916A
0053 00-8
TM 1-1680-377-13&P-1 0053 00
INSTALLATION CONTINUED
Cobra Dual Visor Module Installation
1. Remove TPL, refer to WP 0032 00.
2. Remove the rear retention screw, spring washer, and post fastening the retention assembly to the center rear
of the helmet shell. Retain the screw, washer, and post for reassembly.
REAR RETENTION SCREW
MS098918A
NOTE
Ensure that the holes in the EAL align with the plenum port openings for air cooling. In addition,
the square hole should be located to allow access to the retention assembly mounting hardware.
6. Position the front edge of the EAL between the nape strap pad and the helmet shell at the rear of the helmet.
7. Following the contour of 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.
8. Install keeper strap to helmet shell by routing the strap through EAL.
9. Re-install the rear retention screw, spring washer, and post removed in Step 2.
0053 00-9
0053 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
10. Squeezing the sides of the TPL, re-install it in the helmet. Ensure that the front edge of the TPL is aligned
with the front edge of the EAL and that the hook and pile fasteners are engaged.
11. Attach the earcups to the earcup retaining pads. Check earcup position and adjust as necessary.
0053 00-10
TM 1-1680-377-13&P-1 0054 00
INITIAL SETUP:
Tools and Special Tools ALSE Technician
Screwdriver, Flat-tip (WP 0063 00, Item 27) References
Jewelers Screwdriver Set (WP 0063 00, Item 6) WP 0035 00
Spatula (WP 0063 00, Item 2) WP 0031 00
Materials/Parts WP 0026 00
Cobra Dual Visor Assembly (WP 0065 00, Figure 8) WP 0032 00
Personnel Required
REMOVAL
NOTE
Ensure that the chin strap is disengaged from the D-rings. This will provide easier access to the
helmet for installation.
NOTE
A nut plate (Figure 1, Item 8) on the underside of the helmet shell holds the posts in place.
If the post threads are stripped, remove lining, replace the nut plate, and re-install the EAL
(WP 0035 00).
4. Loosen the four thumbscrews (Figure 1, Item 2) attaching the Cobra visor housing to the helmet shell from
the nut plates inside the helmet shell.
5. Remove the Cobra visor assembly (including visor housing, visor lenses, and track assemblies) from helmet.
0054 00-1
0054 00 TM 1-1680-377-13&P-1
REMOVAL CONTINUED
1
2
3
11
10
4
9 6
MS098923A
6. Unscrew the four thumbscrews (Figure 1, Item 2) attaching the Cobra visor housing to the visor assembly,
and remove the housing (Figure 1, Item 1) from tracks (Figure 1, Item 4, Figure 1, Item 5 and Figure 1, Item
6).
7. Disassemble visors (Figure 1, Item 9 and Figure 1, Item 10) and tracks by removing retaining rings (Figure 1,
Item 3) and bushings (Figure 1, Item 7). Repeat for other side.
8. Inspect disassembled components, refer to WP 0031 00. Replace components as necessary.
INSTALLATION
1. Install the replacement Cobra visor assembly as follows:
a. Place inner visor (Figure 1, Item 9) over lower track (Figure 1, Item 6).
b. Place middle track (Figure 1, Item 5) over inner visor (Figure 1, Item 9). Insert bushings (Figure
1, Item 7) upward through lower track (Figure 1, Item 6) and middle track (Figure 1, Item 5) in that
order.
c. Place upper track (Figure 1, Item 4) over outer visor (Figure 1, Item 10); place both over middle
track (Figure 1, Item 5) and bushings (Figure 1, Item 7). Insert bushings (Figure 1, Item 7) through
upper track (Figure 1, Item 4) and re-install retaining rings (Figure 1, Item 3).
d. Align housing (Figure 1, Item 1) thumbscrew holes over track bushings, and install thumbscrews
(Figure 1, Item 2) through housing and bushings.
e. Position housing and tracks on helmet, aligning bushings over posts from nutplate (Figure 1, Item
8) protruding upward through helmet (two on each side); and start all four thumbscrews.
f. Tighten the four visor assembly thumbscrews (Figure 1, Item 2).
NOTE
Ensure that the holes in the EAL align with the plenum openings for air cooling. In addition, the
square hole should be located to allow access to the retention assembly mounting hardware.
0054 00-2
TM 1-1680-377-13&P-1 0054 00
INSTALLATION CONTINUED
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Screwdriver, Flat-tip (WP 0063 00, Item 27) Cord/Assembly
Gun-type Electrical Heater (WP 0063 00, Item 10) (WP 0065 00, Figure 1 (Sheet 1 of 2), Item 6)
Jewelers Screwdriver Set (WP 0063 00, Item 6)
Drill, Electric (WP 0063 00, Item 9) Personnel Required
Drill, Twist, 19/64 (WP 0063 00, Item 8) ALSE Technician
Materials/Parts References
Microphone WP 0031 00
(WP 0065 00, Figure 1 (Sheet 1 of 2), Item 4) WP 0035 00
Cable Assembly WP 0032 00
(WP 0065 00, Figure 1 (Sheet 1 of 2), Item 3) WP 0041 00
REMOVAL
NOTE
Before beginning this procedure, disengage the chin strap from the D-rings. This will ease the
removal of the components.
NOTE
Keep the earcup assemblies for use during TEMPEST installation.
0055 00-1
0055 00 TM 1-1680-377-13&P-1
REMOVAL CONTINUED
4
MS098932A
Figure 1. Communication Cord Strain Relief Screw and Communication Jack Retaining Plate.
6. Remove the screw (Figure 1, Item 2), spring washer, and post attaching the communication cord strain relief
plate to the helmet shell.
7. Remove the two screws attaching the jack holder plate (Figure 1, Item 3) to the rear of the helmet.
8. Untie the communications cord strain relief plate from the communications cord.
9. Remove the grommet (Figure 1, Item 4) from the rear of the helmet through the inside of the helmet shell.
10. Remove the communications jack retaining plate and pull wire through inside of helmet shell.
11. Remove the foam receiver retainer pad (Figure 2, Item 5) from each earcup (Figure 2, Item 6).
6
8 5
7
MS098933A
NOTE
Keep the receivers; the will be reused during the TEMPEST installation.
12. Using a jewelers screwdriver loosen (do not remove) the set screws attaching the leads (Figure 2, Item 7) to
each receiver (Figure 2, Item 8), and remove the receiver from each earphone shell (Figure 2, Item 6).
0055 00-2
TM 1-1680-377-13&P-1 0055 00
REMOVAL CONTINUED
CAUTION
When removing the communications cord leads from the earcup, handle the grommet only; do
not pull on the wires.
13. Remove the grommet from each earcup.
14. Carefully pull the communications cord leads through hole in each earcup (Figure 2, Item 6). Retain earcup
for use with TEMPEST headset.
15. Remove microphone and Swivel Assembly Boom (SAB) from helmet, refer to WP 0041 00.
16. Carefully remove the communication cord from the helmet shell.
INSTALLATION
1. Ensure the microphone cord (Figure 3, Item 4) is disconnected from the communication cord (Figure 3, Item
1).
6
COMMUNICATIONS CORD 5
P/N 94C8678 1 3
3
2
COMMUNICATIONS CORD 8 9
P/N 1680ALSE162
10
1 11
6
3
12
5 4
MS098934A
2. Insert the jack (Figure 3, Item 5) with attached jack holder through the hole, and install the grommet (Figure
3, Item 6) into the hole in the helmet shell. (If necessary, wet the grommet with plain water to ease insertion.)
3. Slide the shrink tubing over the jack and the jack holder. Shrink the tubing with the heat gun.
4. Install two screws to attach the microphone connector with the jack holder plate to the helmet.
5. If required, re-tie the strain relief plate (Figure 3, Item 3) to the communications cord (Figure 3, Item 1) in the
same manner in which the cord was originally tied.
6. Attach the strain relief plate to the helmet shell with the screw (Figure 3, Item 11), post (Figure 3, Item 7), and
spring washer (Figure 3, Item 10).
0055 00-3
0055 00 TM 1-1680-377-13&P-1
INSTALLATION CONTINUED
WARNING
Ensure that the HGU-56/P crushable earcups are used with the TEMPEST headset.
NOTE
When properly tied, the knot (Figure 3, Item 8) will be between the strain relief plate and the
helmet shell (Figure 3, Item 9).
7. Insert the communications cord leads (Figure 3, Item 2) from the outside of earcup (the original HGU-56/P
earcup) through the holes.
8. Insert the communications cord grommet into the hole in the earcup. For easier insertion, wet the grommet
with plain water if needed.
9. Insert the communications cord leads into the receiver. Using a jewelers screwdriver, tighten the two set
screws.
10. Insert the ear cushion lengthwise into the earcup. Center receiver in earcup, ensuring that the receiver and
the communications cord leads are accessible.
11. Center the receiver in front of the ear cushion. Insert the receiver retainer into the earcup and center it so that
the receiver is seated in the retainer pad.
12. Repeat Steps 7. through 11. for other earcup.
13. Install microphone and SAB, refer to WP 0041 00.
14. Slip the microphone shield (Figure 3, Item 12) over the microphone.
NOTE
Ensure that the holes in the EAL align with the plenum openings for air cooling. In addition, the
square hole should be located to allow access to the retention assembly mounting hardware.
0055 00-4
TM 1-1680-377-13&P-1 0056 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Scissors, Medical (WP 0063 00, Item 47)
Materials/Parts
Edge Beading (WP 0070 00, Item 26)
Synthetic Rubber Adhesive (WP 0070 00, Item 2)
Cleaning Coth (WP 0070 00, Item 5) Personnel Required
Razor Blades (WP 0070 00, Item 16b) ALSE Technician
REPAIR OR REPLACEMENT
1. Peel the worn edge beading away from the MFS or helmet.
2. Rub off old adhesive with a clean cloth. Use a razor blade if necessary.
3. Coat the edge of the MFS or helmet and the edge beading with synthetic rubber adhesive.
4. Install the new edge beading evenly over the edge of the MFS or helmet, allow to dry. Cut off excess edge
beading with shears.
5. Rub off any excess adhesive with a clean cloth.
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Rotary Tool Kit (WP 0063 00, Item 40) Goggles, Eye-protective (WP 0070 00, Item 10)
Drum, Sanding (WP 0063 00, Item 43) Personnel Required
Band, Abrasive (WP 0063 00, Item 44) ALSE Technician
REPAIR OR REPLACEMENT
NOTE
The MFS may be trimmed further to accommodate ANVIS goggles or aviator spectacles if
necessary.
3. Remove the lens caps and lower the night vision goggles. If the goggles clear the MFS and are properly
positioned over the eyes, no trimming is needed. If the goggles contact the shield, trim the shield as follows:
a. Mark a trim line on the shield by tracing along the edge of the goggles where they contact the shield.
Figure 1 shows an example of areas to be trimmed on a shield.
TRIM LINES
MS098967A
0057 00-1
0057 00 TM 1-1680-377-13&P-1
WARNING
Wear eye-protective goggles when trimming the MFS, or chips of the MFS may injure the
eyes.
Wear a respirator when trimming the MFS, or harmful airborne particles may be inhaled.
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 night vision goggles to clear the MFS.
c. Using a rotary cutting tool, trim the shield along the marked trim line.
d. Replace the abrasive band on the sanding drum of the rotary cutting tool as necessary.
e. Reattach the shield and lower the night vision goggles. Ensure that the goggles clear the shield and
are properly positioned over the eyes.
0057 00-2
TM 1-1680-377-13&P-1 0058 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Respirator (WP 0063 00, Item 23)
Shears, Bent Trimmers (WP 0063 00, Item 1)
Polyurethane Coating (WP 0070 00, Item 6a)
Materials/Parts Mixing Sticks (WP 0070 00, Item 11)
Liquid Detergent (WP 0070 00, Item 7) Adhesive (WP 0070 00, Item 1b)
Abrasive Paper, 400 Grit (WP 0070 00, Item 14)
Pad, Isopropyl Alcohol (WP 0070 00, Item 12)
Abrasive Paper, 280 Grit (WP 0070 00, Item 14a) Pad, Scouring, Stainless Steel (WP 0070 00, Item 13)
Abrasive Paper, 220 Grit (WP 0070 00, Item 14b) Tape, Pressure Sensitive (WP 0070 00, Item 23)
Paint Thinner (WP 0070 00, Item 24) Cloth, Cleaning (WP 0070 00, Item 5)
Brush, Paint (WP 0070 00, Item 3) Razor Blades (WP 0070 00, Item 16b)
Can, Paint (1 QT PAINT CAN) (WP 0070 00, Item 4) Adhesive, Synthetic Rubber (WP 0070 00, Item 2)
Primer (WP 0070 00, Item 16) Beading, Edge (WP 0065 00, Figure 2, Item 29)
Primer (WP 0070 00, Item 16a)
Eye-protective Goggles (WP 0070 00, Item 10) Personnel Required
Polyurethane Coating (WP 0070 00, Item 6) ALSE Technician
0058 00-1
0058 00 TM 1-1680-377-13&P-1
REPAIR OR REPLACEMENT
WARNING
Do not repair or use helmet that is damaged beyond the limits set forth in the PMCS charts.
Injury or death may result if you do.
This maintenance action is for cosmetic purposes only. This procedure will not increase
the structural integrity of the helmet shell, nor will it safely repair a shell damaged beyond
the criteria defined in the PMCS Chart.
Hole and Crack Filling
WARNING
Do not fill any holes in the helmet shell other than the four small holes that are used to
mount the oxygen mask bayonet receivers.
Do not fill any cracks in the helmet shell that exceeds the criteria defined in the PMCS
Chart.
NOTE
If the crack is through the black (graphite) layer and into the lighter polyethylene layers the
shell is non-repairable and may not be used.
Before painting, ensure that any associated shell hole or crack filling has been properly
completed.
1. Prepare area to be filled by sanding around holes, paint chips, and cracks using abrasive paper, 220 grit.
2. If only minor sanding is required (if the crack is not through any of the fiber layers), proceed with spot painting
the damaged area as described under REPAIR OR REPLACEMENT.
3. If the repair requires filling existing oxygen mask bayonet receivers mounting holes, clean area to be filled
using isopropyl alcohol pads and apply a temporary backing, i.e., pressure sensitive tape on the inside of the
helmet shell. This will hold the adhesive in place until it fully cures.
NOTE
Follow mixing instructions included with the adhesive.
0058 00-2
TM 1-1680-377-13&P-1 0058 00
Spot Painting
WARNING
To minimize health risks and safety concerns, always wear eye protective goggles, and a
respirator, and appropriate protective clothing when sanding, mixing or spraying primer or paint.
May cause injury or death to personnel.
NOTE
These procedures may also be used for Maxillofacial Shield (MFS) spot painting.
The helmet shell should be spot-painted with the polyurethane coating (also known as
Chemical Agent Resistant Coating (CARC) paint). This coating causes liquid chemical
agents to bead up, allowing for quick, complete decontamination. Spot-painting involves
sanding areas of damaged (cracked, chipped, or peeled) paint and repainting those areas.
1. Wash the surface with a mixture of liquid detergent and water, allow to dry.
2. Using abrasive paper, 220 or 280 grit, remove all loose paint.
3. Using abrasive paper, 400 grit or a stainless steel scouring pad, feather the edges of the solid paint. Ensure
that all damaged paint or corrosion has been removed.
4. Within four hours, clean the area to be painted with paint thinner.
5. Apply the primer over the area to be painted. Apply heavily in the middle and taper it over the edges of the old
paint. Allow the primer to dry, refer to manufacturers instructions.
6. Smooth rough or uneven edges by wet sanding.
7. Apply second coat of primer over the area to be painted. Apply heavily in the middle and taper it over the
edges of the old paint. Allow the primer to dry, refer to manufacturers instructions.
8. Apply the paint over the area. Apply heavily in the middle and taper it toward the edges so that the new paint
is even with the old paint. Allow the top coat to fully cure, refer to manufacturers instructions.
INITIAL SETUP:
Materials/Parts Personnel Required
HGU-56/P Field Change Kit ALSE Technician
(WP 0065 00, Figure 1 (Sheet 1 of 2), Item 22) References
Pad, Isopropyl Alcohol (WP 0070 00, Item 12) WP 0039 00
INSTALLATION
1. Remove the visor assembly from the helmet, refer to WP 0039 00.
VINYL STRIPS
MS098952A
WARNING
Isopropyl alcohol is flammable and toxic to eyes, skin, and respiratory tract. Wear protec-
tive gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well
ventilated areas (or use approved respirator as determined by local safety/industrial hygiene
personnel). Keep away from open flames, sparks or other sources of ignition.
2. Gently clean the inside surface of the visor housing with isopropyl alcohol pad.
3. Use a clean airstream to remove any remaining dust, dirt, or lint.
4. Peel the backing paper from the vinyl strips and install as shown in Figure 1. Ensure that the bottom edges of
the plates are flush with the bottom edge of the visor housing.
5. Re-install the visor assembly, refer to WP 0039 00.
INITIAL SETUP:
NA
0060 00-1
0060 00 TM 1-1680-377-13&P-1
NOTE
FILE A NOTCH IN THE BLADE ABOUT 1/8".
THIS WILL ALLOW THE SCREWDRIVER TO
PASS A SCREW THAT PROTRUDES INTO THE
SLOTTED AREA OF THE SCREW POST. THE
SCREWDRIVER WILL FIT IN THE SLOT OF THE
SLOTTED SCREW POST EVEN IF THE SCREW PROTRUDES.
POST WITH
SCREW PROTRUDING
MS098953A
BULK MATERIAL
Screwdriver, Flat Tip Special
0060 00-2
TM 1-1680-377-13&P-1 0060 00
1" WIDE
PILE FASTENER
(ADHESIVE BACK)
MS098954A
BULK MATERIAL
WOOD BLOCK
HOOK FASTENER TAPE
0060 00-3
0060 00 TM 1-1680-377-13&P-1
1 INCH
IF REPRODUCING THIS
TEMPLATE, MAKE SURE
BOTH OF THESE LINES
1 INCH
SM XL MEASURE 1 INCH ON
LGE
XS THE COPY.
XXS
MED
PLACE THE PROPER SCREW
HOLE OVER THE RIGHT
REAR RETENTION SCREW
XL
SML
XS
ALIGN WITH CAP PLUG (IF PRESENT) XXS
LGE
DRILL CENTER MARK MED
0060 00-4
TM 1-1680-377-13&P-1 0060 00
1 INCH
IF REPRODUCING THIS
TEMPLATE, MAKE SURE
BOTH OF THESE LINES
1 INCH
MEASURE 1 INCH ON XL
THE COPY. LGE SM
XS
XXS
MED
PLACE THE PROPER SCREW
HOLE OVER THE RIGHT
REAR RETENTION SCREW
XL
SML
XS
XXS
LGE
MED DRILL CENTER MARK
0060 00-5
0060 00 TM 1-1680-377-13&P-1
TEMPLATE INSTRUCTIONS
1. Cut out the templates (Figure 3 and Figure 4). Cut out the screw locator circle (above the notation PLACE
THE PROPER SCREW HOLE OVER THE RIGHT REAR RETENTION SCREW) for your helmet size.
2. Cut an X through the "DRILL CENTER MARK" circle for your helmet size.
3. Making sure the template conforms to the shape of helmet, place large hole that you cut out over the retention
screw.
4. Align the curve on the left with the helmet cap plug (if it exists).
5. Align the bottom curve of the template with the bottom edge of the helmet shell.
6. Mark the drill location in the center of the "Drill Center Mark" hole where you cut the X.
BULK MATERIAL
N/A
0060 00-6
TM 1-1680-377-13&P-1
CHAPTER 11
SUPPORTING INFORMATION
FOR
HELMET SYSTEM, AIRCREW INTEGRATED
(HGU-56/P)
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
REFERENCES
SCOPE
This section lists all forms and publications referenced in this manual and required by the user to operate and maintain
the AIHS.
ARMY REGULATIONS (AR)
AR 25-52 Authorized Abbreviations, Brevity Codes, and Acronyms
AR 95-1 Flight Regulations
AR 385-10 The Army Safety Program
AR 385-95 Army Aviation Accident Prevention
AR 700-138 Army Logistics Readiness and Sustainability
AR 710-2 Supply Policy Below the National Level
AR 725-50 Requisitioning, Receipt and Issue System
AR 750-1 Army Materiel Maintenance Policy
DEPARTMENT OF THE ARMY FORMS (DA)
DA Form 2028 Recommended Changes to Publications and Blank Forms
DA Form 2062 Hand Receipt/Annex Number
DA Form 2063-R Prescribed Load List (LRA)
DA Form 2064 Document Register for Supply Actions
DA Form 2405 Maintenance Request Register
DA Form 2407 Maintenance Request
DA Form 2407-1 Maintenance Request-Continuation Sheet
DA Form 2408-22 Helmet and Oxygen Mask/Connector Inspection Record
DA Form 2765-1 Request for Issue or Turn-In
DA Form 3161 Request for Issue or Turn-In
DA Form 3749 Equipment Receipt
DEPARTMENT OF THE ARMY PAMPHLETS (DA PAM)
DA PAM 25-30 Consolidated Index of Army Publications and Blank Forms
DA PAM 710-2-2 Supply Support Activity System: Manual Procedures
DA PAM 738-751 Functional Users Guide to the Army Maintenance
Management System-Aviation (TAMMS-A)
DA PAM 750-8 The Army Maintenance Management System (TAMMS) Users Manual
DEPARTMENT OF DEFENSE FORMS (DD)
DD Form 1574 Serviceable Tag-Materiel
DD Form 1577 Unserviceable (Condemned) Tag-Materiel
DD Form 1577-2 Unserviceable (Repairable) Tag-Materiel
FIELD MANUALS (FM)
FM 38-700 Packaging of Material for Preservation
FM 38-701 Packaging of Material for Packing
STANDARD FORMS (SF)
SF 368 Product Quality Deficiency Report
0061 00-1
0061 00 TM 1-1680-377-13&P-1
TM 1-1500-204-23 (Series) Aviation Unit Maintenance (AVUM) and Aviation Intermediate Mainte-
nance (AVIM) Manual for General Aircraft Maintenance
TM 1-1500-204-23-1 Aviation Unit Maintenance (AVUM) and Aviation Intermediate
Maintenance (AVIM) Manual for General Aircraft Maintenance
(General Maintenance and Practices) Volume 1
TM 9-1270-212-14&P Operators, Organizational, Direct Support and General Support Mainte-
nance Manual (Including RPSTL) for Fire Subsystem, Helmet-Directed
XM128 and Fire Control Subsystem, Helmet-Directed XM136
TM 11-5855-263-10 Operators Manual for Aviators Night Vision Imaging System (ANVIS)
AN/AVS-6(V)1, AN/AVS-6(V)2, and AN/AVS-6(V)1A
TM 55-1660-247-12 Operation, Fitting, Inspection and Maintenance Instructions with Illustrated
Parts Breakdown for MBU-12/P Pressure Demand Oxygen Mask
TM 750-244-1-5 Procedures for Destruction of Aircraft and Associated
Equipment to Prevent Enemy Use
AIR FORCE TECHNICAL ORDERS (TO)
0061 00-2
TM 1-1680-377-13&P-1 0062 00
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
INTRODUCTION
Aviation Maintenance Allocation Chart
The MAC (immediately following the introduction) designates overall authority and responsibility for the performance
of maintenance functions on the identified end item or component. The application of the maintenance functions to the
end item or component shall be consistent with the capacities and capabilities of the designated maintenance level
which are shown on the MAC as:
Field - includes two columns:
"O" which corresponds to Aviation Maintenance Company (AMC)
"F" which corresponds to Aviation Support Battalion (ASB)
The maintenance to be performed below depot and in the field is described as follows:
1. Aviation Maintenance Company (AMC). The primary purpose of the aviation maintenance company is to
support the momentum of offensive operations. Composition of the AMC will be based on type of operations
being supported, nature of the battlefield, and the need for flexibility. AMCs will provide forward positioning
of essential maintenance repair parts and supplies, maximum use of support teams, use of airlift/air drops
for resupply, for maintenance that does not interfere with the tactical plans and operations. AMCs are agile,
mobile, and well equipped. They will carry limited stockpiles of demand supported, essential parts and sup-
plies. The AMC performs battle damage assessment and repair (BDAR) and unit level repairs on Aviation
Life Support Systems (ALSS). The AMC performs production control, quality control, and Maintenance Man-
agement/Maintenance Test Pilot functions. AMCs will rig aircraft for recovery operations. The AMC manages
the battalion maintenance program and operates a central tool room. The AMC conducts forward arming
and refueling. AMCs will be comprised of 3 to 4 modular platoons, which are configured to maintain unit level
operational readiness and aircraft availability:
Headquarters Platoon - Establishes standard operating procedures, receives and processes work
requests, schedules maintenance, maintains status of aircraft, coordinates inspections and test flights
and return of repaired aircraft, enforces quality standards, responsible for safety. Also, obtains, stores,
and issues Classes II, III, IV, and IX, prescribe load list, shop stock and authorized stockage list items.
Airframe Repair Platoon - Tailored to battalion it supports. Performs scheduled and unscheduled
maintenance, troubleshoots faulty components, and removes and replaces aircraft components.
Provides mission capable aircraft to support flight company operations.
Component Repair Platoon - Performs scheduled and unscheduled maintenance, troubleshoots
faulty components, and removes and replaces aircraft components. Performs BDAR and manages
Class IX spare/shop stock. This platoon uses Shop Equipment Contact Maintenance (SECM) trucks
which are multi-capable and self-contained and are used to perform on-site maintenance using en-
hanced power tools, test, measurement, and diagnostic equipment, welding and cutting equipment,
and an air compressor. The SECM truck is highly mobile.
Armament Platoon - Only used in attack battalions and cavalry squadrons. Performs scheduled and
unscheduled maintenance on armament components.
0062 00-1
0062 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
2. Aviation Support Company (ASC) in the Aviation Support Battalion (ASB). Comprised of Headquarters,
Airframe, and Component Repair Platoons. Provides maintenance assistance to aviation units helping them
maintain operational readiness and aircraft availability. Utilizes SECM trucks. Capable of supporting split
based operations in two separate and distinct locations. Performs the following types of maintenance:
a. Intermediate maintenance and logistics support operations.
b. Maintenance actions which require more than 3 days to correct.
c. Phased maintenance and preventive maintenance services.
d. In-depth troubleshooting and diagnosis of airframe and component malfunctions.
e. Repairs airframes and LRU component.
f. Fixes night vision systems, aviation life support systems, aviation electrical and hydraulic components.
g. Limited capability to fabricate hydraulic lines.
h. Repairs engines, prop and rotors, armament, and armament subsystems.
i. Fixes and fuels organic battalion equipment, ground aviation vehicles, and aviation ground support
equipment.
j. Operates and performs field maintenance on aviation ground power units, generator, and ground sup-
port equipment.
k. Battle damage assessment and repair (BDAR).
l. Production control and quality control.
m. Test Pilot functions.
3. Theater Aviation Sustainment Maintenance Group (TASMG). Assists in deployment and redeployment,
provides technical assistance, supports increased operational tempo, sustains Army aviation across the en-
tire spectrum of operations. The TASMG:
a. Provides support to CONUS deploying forces.
b. Provides support to OCUNUS deployed forces.
c. OCONUS aviation maintenance support for contingency and stability and/or support operations.
d. Expands aviation maintenance capabilities of CONUS depots.
e. Classifies and inspects aviation stocks and components.
f. Repairs engines, airframes, armament, composite materials, electrical systems, avionics, hydraulics.
g. Fabricates hydraulics lines.
h. Backup ASB and AMC maintenance functions.
NOTE
Approved item names are used throughout this MAC. Generic terms/nomenclature (if any) are
expressed in parentheses and are not to be considered as official terminology.
This MAC assigns maintenance functions to the lowest level of maintenance, based on past experience and the follow-
ing considerations:
Skills available.
Work time required.
Tools and test equipment required and/or available.
Only the lowest level of maintenance authorized to perform a maintenance function is indicated. If the lowest main-
tenance level cannot perform all tasks of any single maintenance function (e.g., test, repair), then the higher mainte-
nance level(s) that can accomplish additional tasks will also be indicated.
A maintenance function assigned to a maintenance level will automatically be authorized to be performed at any higher
maintenance level.
0062 00-2
TM 1-1680-377-13&P-1 0062 00
INTRODUCTION CONTINUED
A maintenance function that cannot be performed at the assigned level of maintenance for any reason may be evacu-
ated to the next higher maintenance level. Higher maintenance levels will perform the maintenance functions of lower
maintenance levels when required by the commander who has the authority to direct such tasking.
The assignment of a maintenance function will not be construed as authorization to carry the related repair parts or
spares in stock. Information to requisition or otherwise secure the necessary repair parts will be as specified in the
associated RPSTL.
Normally there will be no deviation from the assigned level of maintenance. In cases of operational necessity, at the
request of the lower maintenance level and on a one- time basis, transfer of a maintenance functions to a lower level
may be accomplished by specific authorization of the maintenance officer of the higher level of maintenance to which
the function is assigned. The special tools, equipment, etc., required by the lower level of maintenance to perform this
function will be furnished by the maintenance level to which the function is assigned. This transfer of a maintenance
function to a lower maintenance level does not relieve the higher maintenance level of the responsibility for the func-
tion. The higher level of maintenance will provide technical supervision and inspection of the function being performed
at the lower level.
Maintenance Functions
Maintenance Functions will be limited to and defined as follows:
1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical
characteristics with established standards through examination (e.g., by sight, sound or feel).
2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic or electrical characteristics
of an item and comparing those characteristics with prescribed standards.
3. Service. Operations required periodically to keep an item in proper operating condition,i.e., to clean (in-
cludes decontaminate, when required), to preserve, to drain, to paint or to replenish fuel, lubricants, chemical
fluids or gases.
a. Unpack. To remove from packing box for service when required for the performance of maintenance
operations.
b. Repack. To return item to packing box after service and other maintenance operations.
c. Clean. To rid the item of contamination.
d. Touch up. To spot paint scratched or blistered surfaces.
e. Mark. To restore obliterated identification.
4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or by set-
ting the operating characteristics to specified parameters.
5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measur-
ing or diagnostic equipments used in precision measurement. Consists of comparisons of two instruments,
one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy
of the instrument being compared.
7. Remove/Install. To remove and install the same item when required to perform service or other maintenance
functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part or module
(component or assembly) in a manner to allow the proper functioning of an equipment or system.
8. Paint. To prepare and spray color coats of paint so that the ammunition can be identified and protected. The
color indicating primary use is applied, preferably, to the entire exterior surface as the background color of the
item. Other markings are to be painted as original so as to retain proper ammunition identification.
9. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is au-
thorized by the MAC and assigned maintenance level is shown as the third position code of the Sourse, Main-
tenance, and Recoverability (SMR) code.
10. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installa-
tion, disassembly/assembly procedures, and maintenance actions to identify troubles and restore service-
ability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module
0062 00-3
0062 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
(component or assembly), end item or system. The following definitions are applicable to the "repair" main-
tenance function:
Services. Inspect, test, service, adjust, align, calibrate, and/or replace.
Fault location/troubleshooting. The process of investigating and detecting the cause of equipment
malfunctioning; the act of isolating a fault within a system or Unit Under Test (UUT).
Disassembly/assembly. The step-by-step taking apart (or breakdown) of a spare/functional group
coded item to the level of its least component identified as maintenance significant (i.e., assigned an
SMR code) for the level of maintenance under consideration.
Actions. Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
11. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely service-
able/operational condition as required by maintenance standards in appropriate technical publications.
Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally
return an item to like new condition.
12. Rebuild. Those services/actions necessary for the restoration of unserviceable equipment to a like new con-
dition in accordance with original manufacturing standards. Rebuild is the highest degree of material mainte-
nance applied to Army equipment. The rebuild operation includes the act of returning to zero those age mea-
surements (e.g., hours/miles) considered in classifying Army equipment/components.
0062 00-4
TM 1-1680-377-13&P-1 0062 00
INTRODUCTION CONTINUED
Maintenance Level. The maintenance levels field and sustainment are listed on the MAC with individual columns for
AMC, ASB, TASMG, and Depot that include the work times for maintenance functions at each maintenance level. Work
time presentations such as "0.1" indicate the average time (expressed in manhours in whole hours or decimals) it re-
quires a maintenance level to perform a specified maintenance function. If a work time has not been established, the
columnar presentation will indicate "--". Maintenance levels higher than the level of maintenance indicated are autho-
rized to perform the indicated function.
Tools and Equipment Reference Code. Entry specifies, by code, those common tool sets (not individual tools), com-
mon TMDE, and special tools, special TMDE, and special support equipment required to perform the designated func-
tion.
Tools and Equipment Reference Code. Entry specifies, by code, those common tool sets (not individual tools), com-
mon TMDE, and special tools, special TMDE, and special support equipment required to perform the designated func-
tion.
Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is keyed to the re-
marks.
Explanation of Entries in the Tools and Test Equipment Requirements
Tool or Test Equipment Reference Code. The tool or test equipment reference code correlates with a code used in
tasks and equipment reference code entry of the MAC.
Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.
Nomenclature. Name or identification of the tool or test equipment.
National Stock Number (NSN). The NSN of the tool or test equipment.
Tool Number. The manufacturers part number.
Explanation of Entries in the Remarks
Remarks Code. The code recorded in remarks code entry of the MAC.
Remarks. This entry lists information pertinent to the maintenance function being performed as indicated in the MAC.
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
MAINTENANCE ALLOCATION CHART FOR AIHS
0063 00-1
0063 00 TM 1-1680-377-13&P-1
REPLACE .3 6, 27, 28
0105 Dual Visor Assembly INSPECT .1
REMOVE .2 6, 29
REPLACE .2 6, 29
03 Communication INSPECT .2 C
Enhancement and
Protection System (CEPS)
Kit
REPAIR .5 12, 21, 35,
37
REPLACE 1.0 12, 21, 35,
37
TOOLS OR
TEST EQUIP MAINTENANCE NATIONAL TOOL
REF CODE LEVEL NOMENCLATURE STOCK NUMBER NUMBER
0063 00-2
TM 1-1680-377-13&P-1 0063 00
TOOLS OR
TEST EQUIP MAINTENANCE NATIONAL TOOL
REF CODE LEVEL NOMENCLATURE STOCK NUMBER NUMBER
0063 00-3
0063 00 TM 1-1680-377-13&P-1
TOOLS OR
TEST EQUIP MAINTENANCE NATIONAL TOOL
REF CODE LEVEL NOMENCLATURE STOCK NUMBER NUMBER
0063 00-4
TM 1-1680-377-13&P-1 0064 00
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
INTRODUCTION TO REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL)
INTRODUCTION
SCOPE
This RPSTL lists and authorizes spares and repair parts; special tools; special test, measurement, and diagnostic
equipment (TMDE); and other special support equipment required for performance of Operator and Unit Level Main-
tenance of the AIHS. It authorizes the requisitioning, issue, and disposition of spares, repair parts, and special tools as
indicated by the source, maintenance, and recoverability (SMR) codes.
GENERAL
In addition to the Introduction work package, this RPSTL is divided into the following work packages.
1. Repair Parts List Work Packages. Work packages containing lists of spares and repair parts authorized by
this RPSTL for use in the performance of maintenance. These work packages also include parts which must
be removed for replacement of the authorized parts. Parts lists are composed of functional groups in as-
cending alphanumeric sequence, with the parts in each group listed in ascending figure and item number
sequence. Sending units, brackets, filters, and bolts are listed with the component they mount on. Bulk ma-
terials are listed by item name in FIG. BULK at the end of the work packages. Repair parts kits are listed
separately in their own functional group and work package. Repair parts for reparable special tools are also
listed in a separate work package. Items listed are shown on the associated illustrations.
2. Special Tools List Work Packages. Work packages containing lists of special tools, special TMDE, and spe-
cial support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in the
DESCRIPTION AND USABLE ON CODE (UOC) column). Tools that are components of common tool sets
and/or Class VII are not listed.
3. Cross-Reference Indexes Work Packages. There are two cross reference indexes work packages in this RP-
STL: the National Stock Number (NSN) Index work package and the Part Number (P/N) Index work package.
The National Stock Number Index work package refers you to the figure and item number. The Part Number
Index work package refers you to the figure and item number.
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES
ITEM NO. (Column (1). Indicates the number used to identify items called out in the illustration.
SMR CODE (Column (2). The SMR code containing supply/requisitioning information, maintenance level authoriza-
tion criteria, and disposition instruction, as shown in the following breakout:
0064 00-1
0064 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
0064 00-2
TM 1-1680-377-13&P-1 0064 00
INTRODUCTION CONTINUED
Source Code Application/Explanation
NOTE
Cannibalization or controlled exchange, when authorized, may be used as a source of supply
for items with the above source codes except for those items source coded "XA" or those AV
support items restricted by requirements of AR 750-1.
Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized to use and repair support
items. The maintenance codes are entered in the third and fourth positions of the SMR code as follows:
Third Position. The maintenance code entered in the third position tells you the lowest maintenance level authorized to
remove, replace, and use an item. The maintenance code entered in the third position will indicate authorization to the
following levels of maintenance:
Fourth Position. The maintenance code entered in the fourth position tells you whether or not the item is to be repaired
and identifies the lowest maintenance level with the capability to do complete repair (perform all authorized repair func-
tions).
NOTE
Some limited repair may be done on the item at a lower level of maintenance, if authorized by
the Maintenance Allocation Chart (MAC) and SMR codes.
0064 00-3
0064 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
Maintenance Code Application/Explanation
F- Direct support/AVIM is the lowest level that can do
complete repair of the item.
H- General support is the lowest level that can do complete
repair of the item.
L- Specialized repair activity (enter specialized repair
activity designator) is the lowest level that can do
complete repair of the item.
D- Depot is the lowest level that can do complete repair of
the item.
Z- Nonreparable. No repair is authorized.
B- No repair is authorized. No parts or special tools are
authorized for maintenance of "B" coded item. However,
the item may be reconditioned by adjusting, lubricating,
etc., at the user level.
Recoverability Code. Recoverability codes are assigned to items to indicate the disposition action on unserviceable
items. The recoverability code is shown in the fifth position of the SMR code as follows:
NSN (Column (3). The NSN for the item is listed in this column.
0064 00-4
TM 1-1680-377-13&P-1 0064 00
INTRODUCTION CONTINUED
CAGEC (Column (4). The Commercial and Government Entity Code (CAGEC) is a five-digit code which is used to
identify the manufacturer, distributor, or Government agency/activity that supplies the item.
PART NUMBER (Column (5). Indicates the primary number used by the manufacturer (individual, company, firm, cor-
poration, or Government activity), which controls the design and characteristics of the item by means of its engineering
drawings, specifications, standards, and inspection requirements to identify an item or range of items.
NOTE
When you use an NSN to requisition an item, the item you receive may have a different P/N from
the number listed.
DESCRIPTION AND USABLE ON CODE (UOC) (Column (6). This column includes the following information:
1. The federal item name, and when required, a minimum description to identify the item.
2. P/Ns of bulk materials are referenced in this column in the line entry to be manufactured or fabricated.
3. Hardness Critical Item (HCI). A support item that provides the equipment with special protection from electro-
magnetic pulse (EMP) damage during a nuclear attack.
4. The statement END OF FIGURE appears just below the last item description in column (6) for a given figure
in both the repair parts list and special tools list work packages.
QUANTITY (QTY) (Column (7). The QTY (quantity per figure) column indicates the quantity of the item used in the
breakout shown on the illustration/figure, which is prepared for a functional group, subfunctional group, or an assem-
bly. A "V" appearing in this column instead of a quantity indicates that the quantity is variable and quantity may change
from application to application.
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGES FORMAT AND COLUMNS
1. National Stock Number (NSN) Index Work Package.
STOCK NUMBER Column. This column lists the NSN in National item identification number (NIIN) se-
quence. The NIIN consists of the last nine digits of the NSN.
NSN
(e.g., 5385-01-574-1476)
NIIN
When using this column to locate an item, ignore the first four digits of the NSN. However, the complete NSN should
be used when ordering items by stock number.
FIG. Column. This column lists the number of the figure where the item is identified/located. The figures are
0064 00-5
0064 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
in numerical order in the repair parts list and special tools list work packages.
ITEM Column. The item number identifies the item associated with the figure listed in the adjacent FIG.
column. This item is also identified by the NSN listed on the same line.
2. Part Number (P/N) Index Work Package. P/Ns in this index are listed in ascending alphanumeric sequence
(vertical arrangement of letter and number combinations which places the first letter or digit of each group in
order A through Z, followed by the numbers 0 through 9 and each following letter or digit in like order).
PART NUMBER Column. Indicates the P/N assigned to the item.
FIG. Column. This column lists the number of the figure where the item is identified/located in the repair parts
list and special tools list work packages.
ITEM Column. The item number is the number assigned to the item as it appears in the figure referenced in
the adjacent figure number column.
3. Reference Designator Index Work Package. Reference designators in this index are listed in ascending
alphanumeric sequence (vertical arrangement of letter and number combination which places the first letter
or digit of each group in order "A" through "Z," followed by the numbers "0" through "9" and each following
letter or digit in like order).
REFERENCE DESIGNATOR Column. Indicates the reference designator assigned to the item.
FIG. Column. This column lists the number of the figure where the item is identified/located in the repair parts
list or special tools list work package.
ITEM Column. The item number is the number assigned to the item as it appears in the figure referenced in
the adjacent figure number column.
HOW TO LOCATE REPAIR PARTS
1. When NSNs or P/Ns Are Not Known.
First. Using the table of contents, determine the assembly group to which the item belongs. This is necessary
since figures are prepared for assembly groups and subassembly groups, and lists are divided into the same
groups.
Second. Find the figure covering the functional group or the subfunctional group to which the item belongs.
Third. Identify the item on the figure and note the number(s).
Fourth. Look in the repair parts list work packages for the figure and item numbers. The NSNs and part
numbers are on the same line as the associated item numbers.
2. When NSN Is Known.
First. If you have the NSN, look in the STOCK NUMBER column of the NSN index work package. The NSN
is arranged in NIIN sequence. Note the figure and item number next to the NSN.
Second. Turn to the figure and locate the item number. Verify that the item is the one you are looking for.
3. When P/N Is Known.
First. If you have the P/N and not the NSN, look in the PART NUMBER column of the P/N index work package.
Identify the figure and item number.
Second. Look up the item on the figure in the applicable repair parts list work package.
0064 00-6
TM 1-1680-377-13&P-1 0065 00
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL)
0065 00-1
0065 00 TM 1-1680-377-13&P-1
1 2 3 4
22
21 7
20
8
19
18
10
17
16
11
15
13 12
14
MS103222
0065 00-2
TM 1-1680-377-13&P-1 0065 00
27 24 23
30
26 28
25
CANAL TIPS
29 MS040346
GROUP 00
AIRCREW INTEGRATED HELMET SYSTEM
(AIHS)
FIGURE 1. AIRCREW INTEGRATED HELMET
SYSTEM (AIHS)
0065 00-3
0065 00 TM 1-1680-377-13&P-1
0065 00-4
TM 1-1680-377-13&P-1 0065 00
0065 00-5
0065 00 TM 1-1680-377-13&P-1
END OF FIGURE
0065 00-6
TM 1-1680-377-13&P-1 0065 00
31
2
30
25 29
28
3
17 27
26
4
19 5
18
20
7
21
22
8
24 23
12 9
11 10
16 11
12
13
12
14
15 J174/U
12
14
MS040316
0065 00-7
0065 00 TM 1-1680-377-13&P-1
GROUP 01
HELMET, FLYERS
FIGURE 2. HELMET, FLYERS
0065 00-8
TM 1-1680-377-13&P-1 0065 00
0065 00-9
0065 00 TM 1-1680-377-13&P-1
28 PAOOO 8415-01-395-6841 81996 1680-ALSE-170-1 . Earcup Assembly (See Figure 4 for breakdown) ........ 2
UOC:SZ1-SZ6
29 PAOZZ 8415-00-757-8213 81996 MIL-H-43925 . Beading, Edge .......................................................... 1
UOC:SZ1-SZ6
30 PAOZZ 8415-01-395-3648 81996 1680-ALSE-112-1 . Lining, Helmet, Shock (EAL) ..................................... 1
UOC:SZ1
30 PAOZZ 8415-01-394-9998 81996 1680-ALSE-112-2 . Lining, Helmet, Shock (EAL) ..................................... 1
UOC:SZ2
30 PAOZZ 8415-01-395-3714 81996 1680-ALSE-112-3 . Lining, Helmet, Shock (EAL) ..................................... 1
UOC:SZ3
30 PAOZZ 8415-01-395-3647 81996 1680-ALSE-112-4 . Lining, Helmet, Shock (EAL) ..................................... 1
UOC:SZ4
30 PAOZZ 8415-01-394-9997 81996 1680-ALSE-112-5 . Lining, Helmet, Shock (EAL) ..................................... 1
UOC:SZ5
30 PAOZZ 8415-01-394-9996 81996 1680-ALSE-112-6 . Lining, Helmet, Shock (EAL) ..................................... 1
UOC:SZ6
31 PAOOO 8415-01-394-9999 81996 1680-ALSE-130-1 . Lining, Helmet, Shock (TPL) ...................................... 1
UOC:SZ1
PAOZZ 8415-01-395-1179 81996 1680-ALSE-131-1 . . Liner, Helmet, Cloth (Not Shown) ............................. 1
UOC:SZ1
31 PAOOO 8415-01-395-0000 81996 1680-ALSE-130-2 . Lining, Helmet, Shock (TPL) ...................................... 1
UOC:SZ2
PAOZZ 8415-01-395-1180 81996 1680-ALSE-131-2 . . Liner, Helmet, Cloth (Not Shown) ............................ 1
UOC:SZ2
31 PAOOO 8415-01-395-1555 81996 1680-ALSE-130-3 . Lining, Helmet, Shock (TPL) ...................................... 1
UOC:SZ3
PAOZZ 8415-01-395-1177 81996 1680-ALSE-131-3 . . Liner, Helmet, Cloth (Not Shown) ............................ 1
UOC:SZ3
31 PAOOO 8415-01-395-0001 81996 1680-ALSE-130-4 . Lining, Helmet, Shock (TPL) ...................................... 1
UOC:SZ4
PAOZZ 8415-01-395-1178 81996 1680-ALSE-131-4 . . Liner, Helmet, Cloth (Not Shown) ............................ 1
UOC:SZ4
31 PAOOO 8415-01-395-0002 81996 1680-ALSE-130-5 . Lining, Helmet, Shock (TPL) ...................................... 1
UOC:SZ5
PAOZZ 8415-01-395-1181 81996 1680-ALSE-131-5 . . Liner, Helmet, Cloth (Not Shown) ............................ 1
UOC:SZ5
31 PAOOO 8415-01-395-0003 81996 1680-ALSE-130-6 . Lining, Helmet, Shock (TPL) ...................................... 1
UOC:SZ6
PAOZZ 8415-01-395-4260 81996 1680-ALSE-131-6 . . Liner, Helmet, Cloth (Not Shown) ............................ 1
UOC:SZ6
END OF FIGURE
0065 00-10
TM 1-1680-377-13&P-1 0065 00
MS100112
GROUP 0101
HELMET, RETENTION ASSEMBLY
FIGURE 3. HELMET, RETENTION ASSEMBLY
END OF FIGURE
0065 00-11
0065 00 TM 1-1680-377-13&P-1
1 2 3 4
MS103226
GROUP 0102
SHELL, EARPHONE ASSEMBLY
FIGURE 4. SHELL, EARPHONE ASSEMBLY
END OF FIGURE
0065 00-12
TM 1-1680-377-13&P-1 0065 00
5
3 6
4
J174/U
7
8
7
7
8
3
4
5
6
MS040343
GROUP 0103
COMMUNICATIONS SYSTEM
FIGURE 5. COMMUNICATIONS SYSTEM
END OF FIGURE
0065 00-13
0065 00 TM 1-1680-377-13&P-1
2 3 4 5
1 6
9 8 7
MS040519
GROUP 0104
SWIVEL ASSEMBLY, BOOM (SAB)
FIGURE 6. SWIVEL ASSEMBLY, BOOM (SAB)
END OF FIGURE
0065 00-14
TM 1-1680-377-13&P-1 0065 00
1 2 3
4
5
6
8 7
10
17 11
12
16
13
14
15
MS103224
0065 00-15
0065 00 TM 1-1680-377-13&P-1
GROUP 0105
DUAL VISOR ASSEMBLY
FIGURE 7. DUAL VISOR ASSEMBLY
0065 00-16
TM 1-1680-377-13&P-1 0065 00
END OF FIGURE
0065 00-17
0065 00 TM 1-1680-377-13&P-1
4
3
2
5
11
6
10
MS103230
0065 00-18
TM 1-1680-377-13&P-1 0065 00
GROUP 02
DUAL VISOR ASSEMBLY, COBRA
FIGURE 8. DUAL VISOR ASSEMBLY, COBRA
END OF FIGURE
0065 00-19
0065 00 TM 1-1680-377-13&P-1
2
3
CANAL TIPS
4
MS116075
GROUP 03
COMMUNICATION ENHANCEMENT AND
PROTECTION SYSTEM (CEPS)
FIGURE 9. COMMUNICATION
ENHANCEMENT AND PROTECTION SYSTEM
(CEPS)
END OF FIGURE
0065 00-20
TM 1-1680-377-13&P-1 0065 00
2 3 4 5 6
14
8
9
11 10
13 12
MS040351
GROUP 04
HARDWARE, KIT, MECHANIC EQUIP
FIGURE 10. HARDWARE, KIT, MECHANIC
EQUIP
0065 00-21
0065 00 TM 1-1680-377-13&P-1
END OF FIGURE
0065 00-22
TM 1-1680-377-13&P-1 0065 00
3
MS040350
GROUP 05
MAXILLOFACIAL SHIELD (MFS)
FIGURE 11. MAXILLOFACIAL SHIELD (MFS)
END OF FIGURE
0065 00-23
0065 00 TM 1-1680-377-13&P-1
MS040407
GROUP 06
LIP LIGHT
FIGURE 12. LIP LIGHT
END OF FIGURE
0065 00-24
TM 1-1680-377-13&P-1 0066 00
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
NSN INDEX
5340-01-391-2582 1 29
5305-00-054-5635 7 5
10 1
5305-00-054-5647 1 25
5995-01-391-4400 10 14
5310-00-058-3599 1 24
5305-01-391-4401 7 9
5305-00-147-3230 7 8
8 10
8415-00-163-9048 1 12
5310-01-391-7843 2 6
3 3
5995-01-391-9894 2 9
5310-00-209-1366 10 9
5 2
5305-00-224-0783 7 3
5965-01-392-6179 4 2
5305-00-448-6456 10 8
8415-01-394-6474 1 1
5305-00-465-6745 2 14
2
5310-00-470-3089 7 7
8415-01-394-8021 7 1
5305-00-489-0742 6 6
8415-01-394-8022 1 9
5305-00-490-4581 10 7
8 7
5310-00-543-4652 7 6
8415-01-394-8022 7 17
5325-00-725-0969 7 10
8415-01-394-8023 3 2
8 8
8415-01-394-8024 1 9
8415-00-757-8213 2 29
8415-01-394-8025 2 7
5325-00-814-0430 5 7
8415-01-394-8026 1 8
5340-01-007-8366 5 6
8415-01-394-8027 8 2
5305-01-044-7460 5 3
8415-01-394-8028 8 1
5310-01-063-3044 2 11
8 3
8415-01-074-1622 4 4
8415-01-394-8029 8 1
5310-01-093-0914 2 10
8 5
8 11
8415-01-394-8030 8 1
5310-01-093-0915 10 5
8 4
5965-01-142-7862 2 4a
8415-01-394-8031 1 8
5855-01-151-4229 1 18
7 16
5855-01-151-4230 1 2
8415-01-394-8031 8 6
5340-01-192-9293 1 27
8415-01-394-8032 1 1
8415-01-228-8841 10 13
2
8465-01-229-0171 10 10
8415-01-394-8033 1 1
5965-01-230-2350 1 4
2
5965-01-236-9988 1 21
8415-01-394-8034 1 1
5340-01-273-7158 5 4
2
8415-01-330-6618 4 3
8415-01-394-8035 1 1
5965-01-331-8000 2 25
2
5970-01-339-2635 5 5
8415-01-394-8036 1 1
6240-01-362-4902 12 1
2
5340-01-390-8872 1 23
8415-01-394-8097 8 1
5965-01-390-8873 4 1
8415-01-394-8453 1 14
5965-01-390-8874 2 4
8415-01-394-8454 2 1
5965-01-391-1703 2 27
7
0066 00-1
0066 00 TM 1-1680-377-13&P-1
8415-01-394-8455 2 2 8415-01-449-4029 3 3
8415-01-394-9996 2 30 5855-01-451-7389 1 18
8415-01-394-9997 2 30 6230-01-452-5803 12 1
8415-01-394-9998 2 30 4240-01-455-7982 1 17
8415-01-394-9999 2 31 4240-01-456-4509 1 17
8415-01-395-0000 2 31 4240-01-456-4510 1 17
8415-01-395-0001 2 31 4240-01-456-4511 1 17
8415-01-395-0002 2 31 4240-01-456-4512 1 17
8415-01-395-0003 2 31 4240-01-456-4516 1 17
8415-01-395-0004 2 8 5895-01-457-8419 1 19
8415-01-395-0005 1 7 8475-01-482-9404 7 11
8415-01-395-1177 2 8475-01-482-9405 7 11
8415-01-395-1178 2 5965-01-488-4332 1 28
8415-01-395-1179 2 2 17
8415-01-395-1180 2 8415-01-488-4864 7 14
8415-01-395-1181 2 8415-01-488-4867 7 14
8415-01-395-1555 2 31 8415-01-488-4868 7 12
8415-01-395-2190 2 2 8415-01-488-4930 7 13
8415-01-395-2191 2 2 8415-01-488-4932 7 11
8415-01-395-2192 2 2 8415-01-488-4935 7 11
8415-01-395-2193 1 10 5995-01-503-9248 2 20
8 5965-01-504-0071 2 18
8415-01-395-2194 1 10 5965-01-504-0072 2 18
8 5965-01-504-0073 2 18
8415-01-395-2195 1 10 5965-01-504-0077 2 19
8 8475-01-518-7341 1 11
8415-01-395-2196 1 10 11 1
8 5995-01-519-9234 2 13
8415-01-395-3647 2 30 5 1
8415-01-395-3648 2 30 8415-01-522-4961 2 2
8415-01-395-3714 2 30 8415-01-522-4962 2 2
8415-01-395-4260 2 8415-01-522-4963 2 2
8415-01-395-6841 2 28 8415-01-522-4965 2 2
4 8415-01-522-5310 1 1
5340-01-396-9617 2 15 2
5340-01-397-0321 7 4 8415-01-522-5339 1 1
5975-01-397-4810 2 3 2
6 8415-01-522-5344 1 1
3120-01-398-0293 1 26 2
8 9 8415-01-522-5347 1 1
3120-01-398-0293 7 15 2
5340-01-398-3749 7 2 8415-01-522-5348 1 1
5935-01-399-4401 5 8 2
5965-01-408-8066 1 20 8415-01-522-5364 1 1
5307-01-410-8139 6 8 2
5305-01-411-6402 6 1 6230-01-534-2760 12 2
5995-01-414-3409 1 3 8415-01-558-1082 2 26
5965-01-415-7080 1 5 3 1
5995-01-416-8336 1 6 8415-01-558-3127 3 2
5855-01-440-6614 1 18 5340-01-565-3184 7 12
0066 00-2
TM 1-1680-377-13&P-1 0066 00
5340-01-565-3185 7 12 8415-01-580-5494 1 15
5340-01-567-9222 2 16 8415-01-580-5498 1 15
8415-01-580-5456 1 15 8415-01-580-5499 1 15
8415-01-580-5460 1 15 8415-01-580-5500 1 15
8415-01-580-5465 1 15 8415-01-580-5859 1 15
8415-01-580-5480 1 15 8415-01-590-3520 1 15
8415-01-580-5484 1 15 8415-01-591-3013 1 15
8415-01-580-5489 1 15 8415-01-591-3015 1 15
8415-01-580-5492 1 15 8415-01-591-3020 1 15
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
PART NUMBER INDEX
02D11531-8 1 16
A3260913 1 18
02D11531-9 1 16
AN735-6 8 8
02D11531-10 1 16
CEP199-C01 2 19
02D11531-11 1 16
CEP199-ESHP 2 18
02D11531-12 1 16
CEP199-ESLP 2 18
02D11531-13 1 16
CEP199-ESTP 2 18
1660EG097 1 21
CEP199-X01 2 20
1680-ALSE-101-1 1 1
CEP203-TTC-KIT 1 30
2
9 1
1680-ALSE-101-2 1 1
CEP203-TTC 9 4
2
CEP508-C16 9 3
1680-ALSE-101-3 1 1
CEP900-I04 2 21
2
CEP900-I04E 9 2
1680-ALSE-101-4 1 1
CEP900-K04 1 28
2
2 17
1680-ALSE-101-5 1 1
D6002568 1 4
2
FFS92 10 7
1680-ALSE-101-6 1 1
LP/P DES 5-78 1 12
2
3 3
1680-ALSE-101-7 1 1
MIL-H-43925 2 29
2
ML-14 12 1
1680-ALSE-101-8 1 1
ML-18 12 1
2
ML-24 12 2
1680-ALSE-101-9 1 1
ML-26 12 1
2
ML-8 12 1
1680-ALSE-101-10 1 1
MS16633-4018 7 10
2
8 4
1680-ALSE-101-11 1 1
MS35333-69 7 6
2
MS35335-57 8 10
1680-ALSE-101-12 1 1
MS35335-58 10 9
2
MS35649-224B 7 7
1680-ALSE-105-1 2 2
MS51475-10B 10 4
1680-ALSE-105-2 2 2
MS51861-2C 7 8
1680-ALSE-105-3 2 2
MS51957-1 7 5
1680-ALSE-105-4 2 2
MS51957-12B 1 24
1680-ALSE-105-5 2 2
MS51957-13 8 11
1680-ALSE-105-6 2 2
MS51957-16B 2 14
1680-ALSE-105-7 2 2
MS51957-31B 10 8
1680-ALSE-105-8 2 2
MS51957-4B 7 3
1680-ALSE-109-1 2 7
MS51957-41B 6 6
1680-ALSE-110-1 1 14
00B11104-1 2 23
1680-ALSE-112-1 2 30
00B11105-1 2 22
1680-ALSE-112-2 2 30
0067 00-1
0067 00 TM 1-1680-377-13&P-1
1680-ALSE-112-3 2 30 11 1
1680-ALSE-112-4 2 30 1680-ALSE-194-10 1 22
1680-ALSE-112-5 2 30 1680-ALSE-198-1 2 9
1680-ALSE-112-6 2 30 5 2
1680-ALSE-115-1 2 15 1680-ALSE-199-1 2 27
1680-ALSE-120-1 1 8 1680-ALSE-200-1 2 1
7 16 7
8 2 1680-ALSE-201-1 1 10
1680-ALSE-120-2 1 8 8
1680-ALSE-121-1 1 9 1680-ALSE-201-2 1 10
7 17 8
8 3 1680-ALSE-201-3 1 10
1680-ALSE-121-2 1 9 8
1680-ALSE-123-1 2 6 1680-ALSE-201-4 1 10
1680-ALSE-126-1 2 25 8
1680-ALSE-130-1 2 31 1680-ALSE-202-1 7 1
1680-ALSE-130-2 2 31 1680-ALSE-205-1 7 2
1680-ALSE-130-3 2 31 1680-ALSE-206-1 7 4
1680-ALSE-130-4 2 31 1680-ALSE-209-1 1 27
1680-ALSE-130-5 2 31 1680-ALSE-223-1 11 2
1680-ALSE-130-6 2 31 1680-ALSE-223-2 11 3
1680-ALSE-131-1 2 1680-ALSE-225-1 2 5
1680-ALSE-131-2 2 10 14
1680-ALSE-131-3 2 1680-ALSE-226-1 7 14
1680-ALSE-131-4 2 1680-ALSE-226-2 7 14
1680-ALSE-131-5 2 1680-ALSE-227-1 7 12
1680-ALSE-131-6 2 1680-ALSE-227-2 7 13
1680-ALSE-139-1 2 8 1680-ALSE-238-1 1 29
1680-ALSE-150-1 3 2 10 1
1680-ALSE-161-1 1 3 1680-ALSE-228-10 7 11
1680-ALSE-163-1 2 3 1680-ALSE-228-11 7 11
6 1680-ALSE-255-1 1 7
1680-ALSE-164-1 2 4 1680-ALSE-274-1 8 5
1680-ALSE-165-1 2 10 1680-ALSE-274-9 2 12
8 7 1680-ALSE-277-1 7 9
1680-ALSE-165-2 2 16 8 6
1680-ALSE-166-1 2 11 1680-ALSE-278-1 7 15
1680-ALSE-170-1 2 28 8 9
4 1680-ALSE-287-1 8 1
1680-ALSE-171-1 4 1 1680-ALSE-287-2 8 1
1680-ALSE-174-1 4 2 1680-ALSE-287-3 8 1
1680-ALSE-175-1 4 4 1680-ALSE-287-4 8 1
1680-ALSE-176-1 4 3 1680-ALSE-292-1 1 23
1680-ALSE-177-1 6 2 1680-ALSE-404-1 2 24
1680-ALSE-179-1 6 3 1680-ALSE-408-1 5 1
1680-ALSE-181-1 2 26 1680-ALSE-410-1 2 13
3 1 265897-1 1 18
1680-ALSE-182-1 3 2 5-1-2873-10 1 17
1680-ALSE-188-1 1 26 5-1-2873-20 1 17
1680-ALSE-192-1 1 11 5-1-2873-30 1 17
0067 00-2
TM 1-1680-377-13&P-1 0067 00
5-1-2873-40 1 17 89B7740 10 2
5-1-2873-50 1 17 89B7828-1 10 11
5-1-2873-60 1 17 89B7828-2 10 12
5002530 1 18 89C7767 10 3
5002610 1 2 9A-0015-101 1 15
6011-5 1 19 9A-0015-102 1 15
65A1560B 6 1 9A-0015-103 1 15
67A1809-2 5 7 9A-0015-104 1 15
69A2036 5 3 9A-0016-101 1 15
69A2037-2 5 6 9A-0016-102 1 15
69A2060 5 8 9A-0016-103 1 15
69A2104-3 10 5 9A-0016-104 1 15
69A2136 2 4a 9A-0017-101 1 15
69B2035 5 4 9A-0017-102 1 15
69B2045-9S 5 5 9A-0017-103 1 15
7804056-2 6 9 9A-0017-104 1 15
7804056-4 6 4 9A-0018-101 1 15
78D4056-1 6 8 9A-0018-102 1 15
78D4056-5 6 7 9A-0018-103 1 15
78D4056-6 6 5 9A-0018-104 1 15
80C4839-1 10 13 90B7951-1 1 25
82A5722 10 10 90C7952-2 3 3
88B7622-1 7 12 92A8308 10 6
88B7622-2 7 12 94A8938 1 5
88C7617-1 7 11 94B8811 1 6
88C7617-2 7 11 94C8766 1 20
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
INTRODUCTION
Scope
This work package lists Components Of End Item (COEI) and Basic Issue Items (BII) for the AIHS to help you inventory
items for safe and efficient operation of the equipment.
General
The COEI and BII information is divided into the following lists:
Components Of End Item (COEI). This list is for information purposes only and is not authority to requisition replace-
ments. These items are part of the AIHS. As part of the end item, these items must be with the end item whenever it is
issued or transferred between property accounts. Items of COEI are removed and separately packaged for transporta-
tion or shipment only when necessary. Illustrations are furnished to help you find and identify the items.
Basic Issue Items (BII). These essential items are required to place the AIHS in operation, operate it, and to do emer-
gency repairs. Although shipped separately packaged, BII must be with the AIHS during operation and when it is
transferred between property accounts. Listing these items is your authority to request/requisition them for replace-
ment based on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you find and identify
the items.
Explanation of Columns in the COEI List and BII List
Column (1) Illus Number. Gives you the number of the item illustrated.
Column (2) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning pur-
poses.
Column (3) Description, CAGEC, and Part Number. Identifies the Federal item name (in all capital letters) followed by a
minimum description when needed. The stowage location of COEI and BII is also included in this column. The last line
below the description is the CAGEC (commercial and Government entity code) (in parentheses) and the part number.
Column (4) Usable On Code (UOC). When applicable, gives you a code if the item you need is not the same for different
models of equipment.
Column (5) Unit of Issue (U/I). Indicates the physical measurement or count of the item as issued per the National Stock
Number shown in column (2).
Column (6) Qty Rqr. Indicates the quantity required.
0068 00-1
0068 00 TM 1-1680-377-13&P-1
1 2
TM1168037713&P
TO14P34201
TECHNICAL MANUAL
AVIATION UNIT AND INTERMEDIATE MAINTENANCE MANUAL
INCLUDING REPAIR PARTS AND SPECIAL TOOS LIST
FOR
MS103221
0068 00-2
TM 1-1680-377-13&P-1 0068 00
N/A
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
ADDITIONAL AUTHORIZATION LIST (AAL)
INTRODUCTION
Scope
This work package lists additional items you are authorized for the support of the AIHS.
General
This list identifies items that do not have to accompany the AIHS and that do not have to be turned in with it. These items
are all authorized to you by CTA, MTOE, TDA, or JTA.
Explanation of Columns in the AAL
Column (1) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning pur-
poses.
Column (2) Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N). Identifies the
Federal item name (in all capital letters) followed by a minimum description when needed. The last line below the de-
scription is the CAGEC (in parentheses) and the part number.
Column (3) Usable On Code. When applicable, gives you a code if the item you need is not the same for different mod-
els of equipment.
Column (4) Unit of Issue (U/I). Indicates the physical measurement or count of the item as issued per the National Stock
Number shown in column (1).
Column (5) Qty Recm. Indicates the quantity recommended.
0069 00-1
0069 00 TM 1-1680-377-13&P-1
0069 00-2
TM 1-1680-377-13&P-1 0070 00
SUPPORTING INFORMATION
HELMET SYSTEM, AIRCREW INTEGRATED
HGU-56/P
HGU-56/P WITH CEP
EXPENDABLE AND DURABLE ITEMS
INTRODUCTION
Scope
This work package lists expendable and durable items that you will need to operate and maintain the Aircrew Integrated
Helmet System. This list is for information only and is not authority to requisition the listed items. These items are au-
thorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items).
EXPLANATION OF COLUMNS IN THE EXPENDABLE/DURABLE ITEMS LIST
Column (1) - Item Number. This number is assigned to the entry in the list and is referenced in the narrative instructions
to identify the item (e.g., Use brake fluid (item 5, WP 0098 00).).
Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item. (O =
Unit/AVUM, F = AVIM, D = Depot).
Column (3) - National Stock Number (NSN). This is the NSN assigned to the item which you can use to requisition it.
Column (4) - Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N).
This column provides the other information you need to identify the item.
Column (5) - Unit of Issue (U/I). This code shows the physical measurement or count of an item, such as gallon, dozen,
gross, etc.
0070 00-1
0070 00 TM 1-1680-377-13&P-1
0070 00-2
TM 1-1680-377-13&P-1
CHAPTER 12
GENERAL INFORMATION,
EQUIPMENT DESCRIPTION AND THEORY OF OPERATION
FOR
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
GENERAL INFORMATION
SCOPE
This manual describes preparation, operation and maintenance of the Primary Survival Gear Carrier and Body Armor
Overlay System. It contains a list of authorized items that may be carried in the PSGC and BAOS.
MAINTENANCE FORMS, RECORDS, AND REPORTS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as ap-
plicable) DA Pam 750-8, The Army Maintenance Management System (TAMMS) Users Manual; DA PAM 738-751,
Functional Users Manual for the Army Maintenance Management System - Aviation (TAMMS-A); or AR 700-138, Army
Logistics Readiness and Sustainability.
0071 00-1
0071 00 TM 1-1680-377-13&P-1
LIST OF ABBREVIATIONS/ACRONYMS
0071 00-2
TM 1-1680-377-13&P-1 0071 00
QUALITY OF MATERIAL
Material used for replacement, repair, or modification must meet the requirements of this manual. If quality of material
requirements are not stated in this manual, the material must meet the requirements of the drawings, standards, spec-
ifications, or approved engineering change proposals applicable to the subject equipment.
CALIBRATION
Within the scope of this manual there are no components, accessories, or instruments that require calibration. Special
tools and test equipment shall be calibrated as specified in TB 43-180, Interactive Electronic Technical Manual for Cal-
ibration and Repair Requirements for The Maintenance of Army Materiel.
0072 00-1
0072 00 TM 1-1680-377-13&P-1
LEFT RIGHT
11 12
10 1
9
2
8
5 3
MS040412
Table 1. Major Components of the Primary Survival Gear Carrier (PSGC), GEN I/II.
0072 00-2
TM 1-1680-377-13&P-1 0072 00
Table 1. Major Components of the Primary Survival Gear Carrier (PSGC), GEN I/II. Continued
0072 00-3
0072 00 TM 1-1680-377-13&P-1
1 2
3
13
12
5
11
10
9
6
8
7
MS040411
Table 2. Major Components of the Primary Survival Gear Carrier (PSGC), GEN III.
0072 00-4
TM 1-1680-377-13&P-1 0072 00
Table 2. Major Components of the Primary Survival Gear Carrier (PSGC), GEN III. Continued
0072 00-5
0072 00 TM 1-1680-377-13&P-1
1 2
5 MS040410
Table 3. Additional Components of the Primary Survival Gear Carrier (PSGC), GEN I/II and III.
0072 00-6
TM 1-1680-377-13&P-1 0072 00
Table 3. Additional Components of the Primary Survival Gear Carrier (PSGC), GEN I/II and III. Continued
EQUIPMENT DATA
The PSGC weighs approximately 25 lbs. when fully loaded.
This weight includes the following subassemblies:
Survival Radio
Ammunition
Flashlight
Tourniquet
PSGC Fist Aid Platform
PSGC Signaling Platform
EEP, GEN I/II only (optional)
Utility Pouch, GEN III only (optional)
Enhanced Mobile Equipment (optional)
Survival Radio
Ammunition
Flashlight
Tourniquet
PSGC Fist Aid Items
PSGC Signaling Platform
Utility Pouch
Enhanced Mobile Equipment (optional)
CHAPTER 13
OPERATOR INSTRUCTIONS
FOR
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
CONTROLS AND INDICATORS FOR EXTENDED EQUIPMENT POUCH (EEP), GEN I/II
WARNING
In a Nuclear, Biological, and Chemical (NBC) environment, DO NOT use water or attempt to
drink from the water storage bag. DESTROY the bag and contents. It CANNOT be decontami-
nated.
CAUTION
When using the water storage bag in freezing or near freezing temperatures, the plastic bag will
break. To prevent the bag from breaking, warm the plastic bag BEFORE opening.
The Water Storage Bag (Figure 1) is made of plastic and is capable of holding 5 quarts of water. The bag comes com-
plete with a buckle, snap fastener and carrying strap for easy attachment to personnel or equipment. The Water Stor-
age Bag may be used to store fresh water, protect miscellaneous items from salt water, and may be used as water
wings when inflated and tied together.
BAG, STORAGE
DRINKING WATER
SIZE: B
SPEC. MILB8571D
SPO 10095C5114
MFD. 12/1995
INSPECTION 12/2000
MS098765A
0073 00-1
0073 00 TM 1-1680-377-13&P-1
MS098766A
ASSORTED
FRUIT FLAVORED CANDY
MS098767A
0073 00-2
TM 1-1680-377-13&P-1 0073 00
MS098768A
MS098769A
0073 00-3
0073 00 TM 1-1680-377-13&P-1
EM
E
ST RG
ER EN
IL CY
E
EM TE
ER RIL
S
G EN
CY
G LE
CY
E
ER RI
EN
EM STE
MS098771A
MS038570
0073 00-4
TM 1-1680-377-13&P-1 0073 00
BlastMatch
Refer to Figure 8 and WP 0085 00, BLASTMATCH.
MS098773A
Figure 8. BlastMatch.
MS098775A
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
CONTROLS AND INDICATORS FOR PSGC LEFT HAND POCKET, GEN I/II AND GEN III
MAGAZINE/AMMO POUCH
FLASHLIGHT POUCH
MS098778B
0074 00-1
0074 00 TM 1-1680-377-13&P-1
MS098728A
0074 00-2
TM 1-1680-377-13&P-1 0075 00
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
CONTROLS AND INDICATORS FOR FIRST AID PLATFORM, GEN I/II AND GEN III
MS098745A
MS098781A
0075 00-1
0075 00 TM 1-1680-377-13&P-1
Doxycycline
Used as antibiotic. Refer to Figure 3.
DOXYCYCLINE
HYCLATE
100mg TABLET
DOXYCYCLINE
HYCLATE
100mg TABLET
DOXYCYCLINE
HYCLATE
100mg TABLET
DOXYCYCLINE
HYCLATE
100mg TABLET
NE
DOXYCYCLI
HYCLATE
LET
100mg TAB
MS098782A
Figure 3. Doxycycline.
Loperamide
Used to treat diarrhea. Refer to Figure 4.
MS098783A
Figure 4. Loperamide.
0075 00-2
TM 1-1680-377-13&P-1 0075 00
Acetaminophine
Used for pain relief. Refer to Figure 5.
ASPRIN
325 mg (5gr) TABLET
ASPRIN
325 mg (5gr) TABLET
ASPRIN
325 mg (5gr) TABLET
ASPRIN
325 mg (5gr) TABLET
ASPRIN
325 mg (5gr) TABLET
MS098784A
Figure 5. Acetaminophine.
Bacitracin
Bacitracin Ophthalmic Ointment (2 ea, 0.125 oz tubes) used as disinfectant. Refer to Figure 6 and WP 0086 00,
BACITRACIN.
BA
C
OP ITRAC
HTH IN
OINT ALMI
ME C
STER NT U
I LE SP
BAC
IT
OPH RACIN
THA
OIN L
TME MIC
STER
NT US
ILE P
MS098785A
Figure 6. Bacitracin.
0075 00-3
0075 00 TM 1-1680-377-13&P-1
MS098786A
Mole Skin
Protects skin from abrasions and increased irritation. Refer to Figure 8.
MS098787A
0075 00-4
TM 1-1680-377-13&P-1 0075 00
Sponge
3.5 x 2.5 x 1/8-inch sponge used to collect water. Refer to Figure 9.
MS098788A
Figure 9. Sponge.
Adhesive Bandages
(6 each) Used on minor cuts. Refer to Figure 10. ED
DAMAGED
DAMAG
D
AGE
ED OR
DAM
ED
OR
D
AGE
DAM
NED
DAM
OR
OPE
ILE
ED
OR
ANDAG STERILE
E IF
DO NO
PEN
ED
E
US
PEN
O
DAG E STERIL
RIL E IF
NOT
IF O
STE OT US
DO
ED
E
USE
E
HE ABAN ADHESIVE
RILE
AG
N
M
D NDAGE
NOT
DA
DO
STE
OR
DO
D
E
BANHESIV
NE
IVADEHE AGE
E
ADBHE
OP
E
D IF
GE
E SIV
DAG E
MA E
US
DA
E
BAN ESIV
ABA
T
D
OR E NO
ED IL
PE
N R DO
O
IF
TE S
SE
G
ADH
TU
E NO
RIL
AD AND
DO
E
S
E
ST
AG E
B
A ND ESIV
B H
AD
MS098789A
0075 00-5
0075 00 TM 1-1680-377-13&P-1
HT
CINCH TIG
SSION
COMPRE D
STERILE " ABD PA
E 8" X 10
BANDAG
MS098790A
Tape, Duct
50-inch roll used for various applications. Refer to Figure 12.
MS098791A
0075 00-6
TM 1-1680-377-13&P-1 0075 00
Povidone Iodine
1/2 oz bottle used to disinfect wounds. Refer to Figure 13.
BETADINE
solution
povidoneiodine, 10%
TOPICAL ANTISEPTIC
BACTERICIDE/VIRUCIDE
MUCOUS MEMBRANE
MS098772A
Insect Repellent/Sunscreen
Used to prevent insect bites or sunburn. Refer to Figure 14.
15
SPF
SUNSCREEN
INSECT
REPELLENT
0.3 FL OZ.
SUNSCREEN
INSECT
REPELLENT
0.3 FL OZ.
SUNSCREEN
INSECT
REPELLENT
0.3 FL OZ.
MS098822A
0075 00-7
0075 00 TM 1-1680-377-13&P-1
Eye Patch
One eye patch (Figure 15) used to protect treated eye.
EYE PAT
EYE
PA
TC
H
MS098735
FIRE STARTER
AVIATION
SURVIVAL
SPARKLITE
MS098774A
0075 00-8
TM 1-1680-377-13&P-1 0076 00
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
CONTROLS AND INDICATORS FOR PSGC RIGHT HAND POCKET, GEN I/II AND GEN III
MS098746A
2
6
1
3
MIRROR SIGNALING INSTRUCTIONS
E
W
WARNING
DO NOT EXTEND
SHIELD FOR I.R.
OPERATION
MS098817B
4
0076 00-1
0076 00 TM 1-1680-377-13&P-1
TRIGGER
2 IN.
NOZZLE KIT
SIGNAL
MS098795A
0076 00-2
TM 1-1680-377-13&P-1 0076 00
Lensatic Compass
Used to determine the direction of travel. Refer to Figure 5 and WP 0087 00, LENSATIC COMPASS.
E
W
MS098796A
Distress Marker
Produces intermittent flash of light visible for minimum of five miles. Refer to Figure 6 and WP 0087 00, DISTRESS
MARKER.
WARNING
DO NOT EXTEND
SHIELD FOR I.R.
OPERATION
ON
OFF
MS098797B
0076 00-3
0076 00 TM 1-1680-377-13&P-1
Whistle
The Whistle (Figure 7) is used as a signaling device.
MS098824A
Figure 7. Whistle.
0076 00-4
TM 1-1680-377-13&P-1 0077 00
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER USUAL CONDITIONS FOR AVIATION SURVIVAL AND EGRESS KNIFE (ASEK), GEN
I/II AND GEN III
INITIAL SETUP:
Materials/Parts Personnel Required
Scabbard (WP 0135 00, Figure 8, Item 2) Crew Member
Combat Knife (WP 0135 00, Figure 8, Item 3)
Strap Cutter (WP 0135 00, Figure 8, Item 4)
LEG STRAP
MS100975A
0077 00-1
0077 00 TM 1-1680-377-13&P-1
WARNING
NOTE
The ASEK will be worn on the inside or outside of either calf.
4. Place the ASEK against the outside of the right calf and secure with the side release buckles on the webbing.
Adjust leg straps as necessary for a secure, comfortable fit, refer to Figure 2.
MS098747A
CAUTION
When sitting in the left seat of an OH-58D, the ASEK should be worn on the inside of the right
leg or on the left leg to maximize the room available for right cyclic travel.
5. If ASEK interferes with cyclic travel, reposition ASEK.
0077 00-2
TM 1-1680-377-13&P-1 0078 00
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER USUAL CONDITIONS FOR MAGAZINE/AMMO POUCH, GEN I/II AND GEN III
INITIAL SETUP:
Personnel Required Crew Member
NOTE
The magazine pouch for GEN I/II is located on the far left side of PSGC. Refer to Figure 1.
The magazine pouch for GEN III may be placed in any combination or position on the
PSGC, which it will not interfere with the mission. Refer to Figure 2.
Do not tether ammunition magazines.
1. For GEN III, loop pouch in place on PSGC and secure with snap.
2. Unsnap and open magazine pouch.
3. Place ammunition clips inside the pouch.
4. Close and snap magazine pouch.
RADIO POUCH
MAGAZINE/AMMO POUCH
FLASHLIGHT POUCH
MS098778B
0078 00-1
0078 00 TM 1-1680-377-13&P-1
MS098816C
0078 00-2
TM 1-1680-377-13&P-1 0079 00
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
INITIAL SETUP:
Personnel Required Crew Member
NOTE
Before donning and using the PSGC, perform Operator PMCS (WP 0091 00).
NOTE
If required, holster may be attached to left or right side of PSGC.
3. Attach holster to the PSGC by guiding the holster webbing through the rear wire loop and fold webbing over
to join hook and pile fastener and secure with snap strap, refer to Figure 1.
MS098758A
4. Don PSGC.
0079 00-1
0079 00 TM 1-1680-377-13&P-1
WARNING
Utilization of PSGC Leg Restraint Straps is mandatory. Failure to properly secure leg straps will
degrade the PSGC extraction/restraint capabilities and may result in serious personal injury.
5. Ensuring the leg straps are not twisted, buckle the left and right leg restraint straps, refer to Figure 2.
MS098752A
WARNING
The two front buckles will be secured at all times when in use. Failure to properly secure
front buckles will degrade the PSGC extraction/restraint capabilities and may result in serious
personal injury.
7. Buckle the front upper and lower torso straps, refer to Figure 3.
0079 00-2
TM 1-1680-377-13&P-1 0079 00
MS098757A
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
INITIAL SETUP:
Personnel Required WP 0516 00
Crew Member WP 0091 00
References
WARNING
Do not place survival items on the back, aligned with the spine of the wearer, this may cause
spinal injuries during a crash sequence.
NOTE
Before donning and using the PSGC perform Operator PMCS (WP 0091 00).
Equipment pouches may be attached in accordance to the items issued to the individual.
Tourniquet will be placed on the left side shoulder strap.
The extraction strap will be placed on the upper right side of the PSGC main pocket.
If utilizing the utility pouch for first aid items, place the pouch on the left side of the wearer.
The PSGC GEN III has a radio pouch, multi-purpose pouch (flashlight/tourniquet), mag-
azine pouches, WED pouch and AWIS EME pouch that may be used in any combination
and position which will not interfere with the mission.
3. If required, holster may be attached to PSGC in different configurations, refer to WP 0081 00.
4. Don PSGC.
0080 00-1
0080 00 TM 1-1680-377-13&P-1
WARNING
The two front buckles will be secured at all times when in use. Failure to properly secure
front buckles will degrade the PSGC extraction/restraint capabilities and may result in serious
personal injury.
NOTE
The zipper is not part of the extraction/retention capabilities. The zipper may be unsecured
while in flight or during extraction. Functionality of the zipper does not impair use of the PSGC.
5. Buckle the front upper and lower torso straps and close zipper.
WARNING
Utilization of PSGC Leg Restraint Straps is mandatory. Failure to properly secure leg straps will
degrade the PSGC extraction/restraint capabilities and may result in serious personal injury.
6. Ensuring the leg straps are not twisted, buckle the left and right leg restraint straps.
0080 00-2
TM 1-1680-377-13&P-1 0081 00
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER USUAL CONDITIONS FOR PISTOL HOLSTER RIGGING, GEN III
INITIAL SETUP:
Personnel Required EM 0250 Shoulder Rigging Video
Crew Member EM 0250 Leg Rigging Video
TM 9-1005-317-10
References
NOTE
Retain plastic tool used to remove Thumb Break.
1. Use plastic tool to loosen hook and pile fastener securing Thumb Break (Figure 1, Item 1) and remove from
holster.
1
2
MS040358
2. Unsnap and remove grip retention strap (Figure 1, Item 2) from holster.
3. Place two 3/4-inch vertical straps through the metal loop on the holster flap, refer to Figure 2.
0081 00-1
0081 00 TM 1-1680-377-13&P-1
METAL LOOP
VERTICAL
STRAPS
MS040357
4. Secure holster flap by weaving vertical straps through webbing loops on holster.
5. Loop the release webbing adapter (Figure 3) through the second horizontal webbing on the holster and
secure snap.
RELEASE
WEBBING
ADAPTER
MS040356
0081 00-2
TM 1-1680-377-13&P-1 0081 00
NOTE
If mission requires that a weapon will be worn, a holster may be attached to the left or right side
of the PSGC.
NOTE
Strap should be snug against hammer of pistol. If it is not, insert a screwdriver, thin stick, or
similar instrument between strap and holster to separate hook and pile; then adjust height of
strap such that it will fit snug over pistol hammer; then press hook and pile together again.
5. Pull the hammer retention strap at the top outside of the holster across the hammer and secure the snap
fastener on the inside of the holster.
6. Pull the grip retention strap over the pistol grip and secure the snap fastener on the side of the holster.
7. Load ammunition magazine, refer to TM 9-1005-317-10.
8. Insert magazine into magazine holder on front of holster.
9. Securely fasten the snap on the retention strap.
HOLSTER ATTACHED
TO VEST
MS098729A
0081 00-3
0081 00 TM 1-1680-377-13&P-1
NOTE
The holster is designed to attach to the left or right rear loops on the PSGC. It can be used
attached to the wearers belt or worn as a left or right handed shoulder holster.
NOTE
Strap should be snug against hammer of pistol. If it is not, insert a screwdriver, thin stick, or
similar instrument between strap and holster to separate hook and pile; then adjust height of
strap such that it will fit snug over pistol hammer; then press hook and pile together again.
SHOULDER
HOLSTER
MS098731A
0081 00-4
TM 1-1680-377-13&P-1 0081 00
NOTE
Strap should be snug against hammer of pistol. If it is not, insert a screwdriver, thin stick, or
similar instrument between strap and holster to separate hook and pile; then adjust height of
strap such that it will fit snug over pistol hammer; then press hook and pile together again.
5. Pull the hammer retention strap at the top outside of the holster across the hammer and secure the snap
fastener on the side of the holster.
6. Pull the grip retention strap over the pistol grip and secure the snap fastener on the side of the holster.
7. Load an ammunition magazine, refer to TM 9-1005-317-10.
8. Insert magazine into magazine pouch located on forward side of holster.
9. Securely fasten the snap on the retention strap.
10. Release the holster belt strap by releasing the snap fastener and hook and pile fastener on the extender belt
strap at the top of the holster.
NOTE
The holster is designed to attach to the left or right rear loops on the PSGC. It can be used
attached to the wearers belt or worn as a left or right handed shoulder holster.
11. Locate two rectangular metal loops under right or left pocket of PSGC.
12. Insert holster extender belt strap through rear loop and fold belt strap on itself, attaching hook and pile
fastener.
13. Secure end of extender belt strap inside webbing strap and fasten retention snap.
0081 00-5
0081 00 TM 1-1680-377-13&P-1
MS100973A
0081 00-6
TM 1-1680-377-13&P-1 0082 00
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER USUAL CONDITIONS FOR CYCLIC SWEEP, GEN I/II AND GEN III
INITIAL SETUP:
Personnel Required Pilot/Co-Pilot
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER USUAL CONDITIONS FOR AIRCREW RESTRAINT ASSEMBLY, GEN I/II AND GEN
III
INITIAL SETUP:
Materials/Parts Personnel Required
Snap Link, Rear (WP 0135 00, Figure 7, Item 4) Non-rated Aircrew Member
Extension Tether (WP 0135 00, Figure 7, Item 3)
Personal Restraint Tether
(WP 0135 00, Figure 7, Item 1)
ABRASION COVER
LOCKING CARABINER
MS098730A
2. Attach locking carabiner with the extension tether (ET) to the upper back retention loop of PSGC, refer to
Figure 1.
3. Secure ET to the retention loop utilizing the locking carabiner, refer to Figure 1.
0083 00-1
0083 00 TM 1-1680-377-13&P-1
WARNING
Utilization of PSGC Leg Restraint Straps is mandatory. Failure to properly secure leg
straps will degrade the PSGC extraction capability and may result in operator injury.
Improper connection of the PRT to the ET could prevent egress from the aircraft during an
emergency.
The PRT cannot be used for hoisting and should only be used for securing personnel to
aircraft.
NOTE
The CRA securely connects the aircrew to a helicopter authorized attachment point.
4. Secure the Personal Restraint Tether (PRT) to the ET to form the Crew Restraint Assembly (CRA), ensuring
the quick ejector snap is attached to the ET, refer to Figure 2.
PERSONAL RESTRAINT
TETHER
SNAP LINK
MS098756B
0083 00-2
TM 1-1680-377-13&P-1 0084 00
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER USUAL CONDITIONS FOR INSERTION AND EXTRACTION OPERATIONS, GEN III
INITIAL SETUP:
Personnel Required Crew Member/Medic
WARNING
The PSGC Extraction Strap (ES) and SRT are used for emergency extraction purposes only.
Do not use the ES or SRT for repeated insertion operations. Failure to comply may result in
injury or death to personnel.
NOTE
The PSGC is approved for multiple insertion and extraction operations.
The locking carabiner must meet ANSI Z359.1 requirements and have a tensile strength
of 5000 lbs., gate face strength of 220 lbs., and a side of gate strength of 350 lbs.
INSERTION AND EXTRACTION OPERATIONS
1. Ensure locking carabiner is secured to both front lifting loops on the PSGC.
2. Secure hoist to locking carabiner on PSGC for insertion and extraction.
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER USUAL CONDITIONS FOR EXTENDED EQUIPMENT POCKET (EEP), GEN I/II
INITIAL SETUP:
Personnel Required Crew Member
EEP POCKET
DRINKING WATER STORAGE BAG
1. Fill storage bag (Figure 1) with water collected.
2. Roll top of bag and secure with snap.
BAG, STORAGE
DRINKING WATER
SIZE: B
SPEC. MILB8571D
SPO 10095C5114
MFD. 12/1995
INSPECTION 12/2000
MS098765A
0085 00-1
0085 00 TM 1-1680-377-13&P-1
MS098766A
ASSORTED
FRUIT FLAVORED CANDY
MS098767A
0085 00-2
TM 1-1680-377-13&P-1 0085 00
MS098768A
MS098769A
0085 00-3
0085 00 TM 1-1680-377-13&P-1
EM
E
ST RG
ER EN
IL CY
E
EM TE
ER RIL
S
G EN
CY
G LE
CY
E
ER RI
EN
EM STE
MS098771A
NOTE
Before attempting to start a fire, gather wood chips, leaves, twigs to increase the size of
the fire as it develops.
When an individual cannot pull the fire tabs apart, due to injury of an arm or hand. The fire
tabs can be roughened or fluffed by using one hand to hold the fire tab and snaring it on a
sharp pointed object, exposing some inner fibers.
Avoid touching or matting inner fibers as these fluffed fibers ignite more readily.
If tinder is frozen, hold in closed hand for 30 seconds before lighting.
NOTE
If the lighter gets wet, shake to remove excess water and blow on the flint wheel.
3. Place the tip of the index finger on the flint wheel and with medium pressure rapidly move the index finger in
the direction indicated by Figure 7. This movement will cause a shower of sparks to fall on the fluffed tinder,
igniting it.
0085 00-4
TM 1-1680-377-13&P-1 0085 00
MS038570
BLASTMATCH
1. Gently raise striker button tab to release the end cap, exposing the spring-loaded flint bar.
2. Slide end cap to clear flint bar and rotate cap to rear of BlastMatch body.
3. Fit cap on rear of BlastMatch body. (Cap will sit loosely yet securely)
CAUTION
Allowing flint bar to bend out of line with BlastMatch body may snap off or damage striker bar.
Do not pull striker tab back or away from the BlastMatch body.
4. Place thumb on striker tab and press down with medium pressure. Plunge the body of the BlastMatch down
the striker bar, making sure that the flint bar remains in line with BlastMatch body.
MS098773A
Figure 8. BlastMatch.
0085 00-5
0085 00 TM 1-1680-377-13&P-1
MS098775A
0085 00-6
TM 1-1680-377-13&P-1 0086 00
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER USUAL CONDITIONS FOR FIRST AID PLATFORM, GEN I/II AND GEN III
INITIAL SETUP:
Personnel Required Crew Member
MS098781A
DOXYCYCLINE
Consult with the appropriate medical personnel for proper dosing. Refer to Figure 2.
DOXYCYCLINE
HYCLATE
100mg TABLET
DOXYCYCLINE
HYCLATE
100mg TABLET
DOXYCYCLINE
HYCLATE
100mg TABLET
DOXYCYCLINE
HYCLATE
100mg TABLET
E
DOXYCYCLIN
HYCLATE
LET
100mg TAB
MS098782A
Figure 2. Doxycycline.
0086 00-1
0086 00 TM 1-1680-377-13&P-1
LOPERAMIDE
Consult with the appropriate medical personnel for proper dosing. Refer to Figure 3.
MS098783A
Figure 3. Loperamide.
ACETAMINOPHINE
Consult with the appropriate medical personnel for proper dosing. Refer to Figure 4.
ASPRIN
325 mg (5gr) TABLET
ASPRIN
325 mg (5gr) TABLET
ASPRIN
325 mg (5gr) TABLET
ASPRIN
325 mg (5gr) TABLET
ASPRIN
325 mg (5gr) TABLET
MS098784A
Figure 4. Acetaminophine.
0086 00-2
TM 1-1680-377-13&P-1 0086 00
BA
C
OP ITRAC
HTH IN
OINT ALMI
M C
STER ENT US
I LE P
BAC
IT
OPH RACIN
THA
OIN L
TME MIC
NT
STER USP
ILE
MS098785A
Figure 5. Bacitracin.
WARNING
Do not place any part of the CTW that the first aider has handled on the sucking chest wound.
Dressings, bandages, and the CTW should be snug, not tight. In the cold, protect the injury from
the cold. Check for frostbite.
NOTE
The CTW is not 100% sterile. Always apply polysporin, polymyxin B sulfate, Bacitracin
Zinc, or any approved antiseptic to the wounded area before applying the CTW.
CTW is a "no stick" plastic first aid field dressing. It may be applied directly to cuts,
punctures, tears, and abrasions. The CTW is especially effective for the control of
bleeding in extreme cold weather.
0086 00-3
0086 00 TM 1-1680-377-13&P-1
MS098786A
MOLE SKIN
Cut piece 1/4-inch larger than affected area and apply mole skin over affected area. Refer to Figure 7.
MS098787A
SPONGE
Collect water with sponge and squeeze into container. Refer to Figure 8.
MS098788A
Figure 8. Sponge.
0086 00-4
TM 1-1680-377-13&P-1 0086 00
ADHESIVE BANDAGES
Remove protective cover and apply to affected area. Refer to Figure 9.
ED
DAMAGED
DAMAG
GED
ED OR
AMA
ED
D
STER T USE IF OPEN
AG
OR
GED
DAM
ED
AMA
N
OR
OPE
D
ILE
ED
OR
ANDAG STERILE
E IF
DO NO
PEN
ED
E
US
N
O
DAG E STERIL
OPE
RIL E IF
NOT
STE OT US
E IF
DO
ED
E
HE ABAN ADHESIVE
RILE
US
AG
N
M
D NDAGE
OT
DA
DO
STE
ON
OR
ED
E
BANHESIV
D
EN
IVADEHE AGE
ADBHE
OP
E
D IF
GE
E SIV
DAG E
MA E
US
DA
E
BAN ESIV
ABA
T
D
OR LE NO
ED I
PE
N R DO
O
IF
TE S
SE
ADH
TU
E NO
RIL
AD AND
DO
E
S
E
ST
AG E
B
A ND ESIV
B H
AD
MS098789A
WARNING
WARNING
Product may contain natural rubber latex which may cause allergic reactions.
Open package and follow instructions below. Refer to Figure 10.
0086 00-5
0086 00 TM 1-1680-377-13&P-1
HT
CINCH TIG
SSION
COMPRE D
STERILE " ABD PA
E 8" X 10
BANDAG
MS098790A
TAPE, DUCT
Cut duct tape to desired length and apply as needed. Refer to Figure 11.
MS098791A
0086 00-6
TM 1-1680-377-13&P-1 0086 00
POVIDONE IODINE
1. Invert bottle and squeeze gently (Figure 12).
BETADINE
solution
povidoneiodine, 10%
TOPICAL ANTISEPTIC
BACTERICIDE/VIRUCIDE
MUCOUS MEMBRANE
MS098772A
WARNING
NOTE
May be covered with gauze or adhesive bandages.
0086 00-7
0086 00 TM 1-1680-377-13&P-1
INSECT REPELLENT/SUNSCREEN
Open packet and apply as needed. Refer to Figure 13.
15
SPF
SUNSCREEN
INSECT
REPELLENT
0.3 FL OZ.
SUNSCREEN
INSECT
REPELLENT
0.3 FL OZ.
SUNSCREEN
INSECT
REPELLENT
0.3 FL OZ.
MS098822A
EYE PATCH
1. Open package (Figure 14).
2. Place pad on wounded eye and secure with duct tape.
EYE PAT
EYE
PA
TC
H
MS098735
0086 00-8
TM 1-1680-377-13&P-1 0086 00
NOTE
Before attempting to start a fire, gather wood chips, leaves, twigs to increase the size of
the fire as it develops.
When an individual cannot pull the fire tabs apart, due to injury of an arm or hand. The fire
tabs can be roughened or fluffed by using one hand to hold the fire tab and snaring it on a
sharp pointed object, exposing some inner fibers.
Avoid touching or matting inner fibers as these fluffed fibers ignite more readily.
If tinder is frozen, hold in closed hand for 30 seconds before lighting.
NOTE
If the lighter gets wet, shake to remove excess water and blow on the flint wheel.
3. Place the tip of the index finger on the flint wheel and with medium pressure rapidly move the index finger in
the direction indicated by Figure 15. This movement will cause a shower of sparks to fall on the fluffed tinder,
igniting it.
MS038570
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER USUAL CONDITIONS FOR RIGHT HAND POCKET ASSEMBLY, GEN I/II AND GEN
III
INITIAL SETUP:
Personnel Required Crew Member
WARNING
CAUTION
After flare is in projector, do not pull back on trigger unless you are ready to fire flare. Do not fire
toward or lead the aircraft. Serious damage can result if aircraft is hit by flare, thereby hampering
your rescue.
1. Remove flare from plastic retainer and insert flare into projector, refer to Figure 1.
2. Hold projector firmly in hand, point it straight up and pull trigger down with thumb.
3. Release trigger with a sharp sudden motion.
PROJECTOR
TRIGGER
2 IN.
NOZZLE KIT
SIGNAL
0087 00-1
0087 00 TM 1-1680-377-13&P-1
MS098795A
LENSATIC COMPASS
NOTE
The arrow on the compass dial always points to magnetic "NORTH".
Holding objects in the vicinity of the lensatic compass which contain iron or steel, or other
types of compasses, will cause the lensatic compass to give incorrect readings.
1. Hold the compass erect so that the lubber line (direction indicator) is parallel to your line of sight.
2. Turn the plastic top until the lubber line is over the NORTH arrow. Your course heading may then be read on
a line drawn through the sights.
E
W
MS098796A
0087 00-2
TM 1-1680-377-13&P-1 0087 00
DISTRESS MARKER
1. Hold the Distress Marker.
2. Push up on the ON/OFF switch to turn ON the Distress Marker.
3. Push down on the ON/OFF switch to turn OFF the Distress Marker.
WARNING
DO NOT EXTEND
SHIELD FOR I.R.
OPERATION
ON
OFF
MS098797B
WHISTLE
Place whistle (Figure 5) in mouth and blow outward to make sound.
MS098824A
Figure 5. Whistle.
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER UNUSUAL CONDITIONS FOR AIRCREW EXTRACTION, GEN I/II AND GEN III
INITIAL SETUP:
Personnel Required Crew Member
UNUSUAL ENVIRONMENT/WEATHER
WARNING
Utilization of PSGC Leg Restraint Straps is mandatory. Failure to properly secure leg straps will
degrade the PSGC extraction/restraint capabilities and may result in serious personal injury.
2. Secure SAR aircraft extraction hook to the carabiner for aircrew extraction.
CARABINER
LIFTING
LOOPS
MS098753A
OPERATOR INSTRUCTIONS
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATION UNDER UNUSUAL CONDITIONS FOR SAFETY RESTRAINT TETHER (SRT), GEN I/II AND
GEN III
INITIAL SETUP:
Personnel Required Crew Member
WARNING
Never approach an operating rotary-wing aircraft from the rear! Death or severe injury
could occur if the pilot does not see you and rotates the aircraft. Always approach an
operating aircraft from the front or side and only when signaled to do so by the pilot or
crewmember. Minimize exposure to the front of any weapons systems.
Pilots must take into consideration lateral center of gravity (CG) when attempting any
externally carried rescue. Pilot must retain enough cyclic force to counter the weight of the
rescuee. Externally carried rescues will be flown the shortest practical distance to remove
the rescuee from immediate extreme danger.
Pilots should limit forward airspeed to 60 knots and only exceed this speed if required by
the tactical situation. Pilots/crew should monitor the status of the rescuee. If the rescuee
falls from his/her seating he/she will be retained by the SRT, however the rescuees lower
body/legs may be lower than the landing gear. Ensure he/she is clear of the landing gear
before landing.
The Safety Restraint Tether is ONLY FOR USE IN EMERGENCY SITUATIONS and must
be kept in serviceable condition. Aircrew practice of SRT attachment to the aircraft will
be limited to nonoperating aircraft, parked in an approved landing or tiedown area. The
SRT is intended to be used with the extraction harness of the AIRSAVE and PSGC (or
the SARVIP and the SRU-21/P when modified with extraction harness). Use with other
systems may result in injury.
The Safety Restraint Tether has a rated strength of 3000 pounds and a one-time pull test
strength of 5000 pounds. Do not use the tether if any of the bar tacks is loose, frayed,
or missing. Do not use the tether if the nylon webbing is worn, frayed, cut, or has been
soaked by POL (Petroleum, Oil Lubricant) products. Turn it in and get a new tether.
UNUSUAL ENVIRONMENT/WEATHER
0089 00-1
0089 00 TM 1-1680-377-13&P-1
AH-1, COBRA
1. On the AH-1, the right-side or left-side ammunition bay doors can be lowered. Ensure the ammo canisters
are securely locked in place.
2. Attach the SRT to the forward handle of the 20mm ammunition container by looping the SRT through the
handle and pulling the loop snug.
3. Sit on the open door, facing outward, bracing feet on the aircraft skid. Attach the other end of the SRT to the
carabiner on the front lifting loops of the PSGC.
4. Depending on seating position and your size, use any safe method (such as doubling-over the SRT) to obtain
a stable attachment to the aircraft as possible. Use available uninjured hands for additional bracing and once
you have obtained the most stable position possible, signal the pilot your readiness for liftoff. If two SRTs are
available, you may attach yourself to both the front and rear handles of the 20mm ammunition canister.
AH-64, APACHE
Attaching points on the AH-64 are: right-side handhold located just aft of the pilots door; and left-side center step just
aft of the pilots left window.
1. For attachment to the right side, sit on the right forward avionics bay (FAB) with your back against the leading
edge of the wing support, refer to Figure 1.
2. Double-over the SRT, loop it through the handhold, and attach the SRT to the carabiner on the front lifting
loops of the PSGC.
3. Use the handhold, taut SRT, and wing support for hand/arm/back bracing points and the lower step and the
top of the FAB for foot/leg bracing points.
4. For attachment to the left side, sit on the left (FAB) with your back against the leading edge of the wing
support.
5. Double-over the SRT, loop it through the center step and attach the SRT to the carabiner on the front lifting
loops of the PSGC.
6. Use the top step, taut SRT, and wing support for hand/arm/back bracing points and the lower step and the
top of the FAB for foot/leg bracing points.
7. Once you have obtained the most stable position possible, then signal the pilot your readiness for liftoff.
0089 00-2
TM 1-1680-377-13&P-1 0089 00
MS100954A
Figure 1. Apache.
OH-58, KIOWA
WARNING
OH-58 pilots must take into consideration lateral center of gravity (CG) when attempting any
externally carried rescue. Pilot must retain enough cyclic force to counter the weight of the
rescuee.
On the OH-58, the attaching points are the hard-points on the left and right weapons pylons.
1. Sit straddling the weapon launcher, facing the rear of the aircraft, refer to Figure 2.
2. Loop the SRT around the hard-point and attach the ends to the carabiner on the front lifting loops of the
PSGC.
3. For additional security lean forward over the weapon launcher and grasp the hard-point and the launcher to
stabilize your position.
4. Once you have obtained the most stable position possible, then signal the pilot your readiness for liftoff.
0089 00-3
0089 00 TM 1-1680-377-13&P-1
MS100996A
Figure 2. Kiowa.
0089 00-4
TM 1-1680-377-13&P-1
CHAPTER 14
OPERATOR MAINTENANCE INSTRUCTIONS
FOR
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
(NSN: 8415-01-513-8143)
OPERATOR MAINTENANCE
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PROCEDURES INTRODUCTION
CAUTION
Replace equipment when exposed to an aircraft mishap. Replace entire fall arrest system
(including PSGC, ET and PRT) in the event of a fall from the aircraft which induces a dynamic
arrest force.
NOTE
Any faults found during PMCS will render the vest unserviceable. Turn equipment into the
Aviation Life Support Equipment Technician (ALSE).
INTRODUCTION
Preventive Maintenance Checks and Services (PMCS) are performed to keep equipment in operating condition.
Checks are used to find, correct, or report problems. PMCS is done every day equipment is operated.
When performing any PMCS procedure or routine check, observe all safety warnings and cautions.
If your equipment must be in operation at all times, check and service those items that can be checked and serviced
without disturbing operation. Make complete checks and services when equipment can be shut down.
Defects discovered should be corrected as soon as possible. All deficiencies, together with corrective action taken,
should be recorded on forms prescribed for maintenance. See DA PAM 738-751.
PMCS TABLE EXPLANATION
"Item No." Column
This column contains a number for each procedure to be performed.
"Interval" Column
Interval column of your PMCS table tells you when to do a certain check or service. Standard intervals are:
Before - Do before you begin operating equipment or pre-flight.
During - Do while operating equipment.
After - Do after operating equipment.
Periodic - Do once per 180 day interval.
Annual - Do once per 3606 interval.
0090 00-1
0090 00 TM 1-1680-377-13&P-1
NOTE
Terms "ready/available" and "mission capable" refer to same status: equipment is on hand and
is able to perform its combat missions (see AR 700-138).
If you find something wrong and you cant fix it yourself, or you are not authorized to, or you do not have tools, test
equipment, parts, documentation, or training to fix it yourself, inform your supervisor, and request assistance from next
higher level of maintenance.
0090 00-2
TM 1-1680-377-13&P-1 0091 00
OPERATOR MAINTENANCE
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES, GEN I/II AND III
INITIAL SETUP:
References WP 0099 00
1 B/A .5 PSGC/BAOS Inspect overall condition of each major com- Any component is
Major ponent: PSGC/BAOS, ASEK, extension tether missing. Turn into
Compo- (non-rated crewmembers only), pouches and ALSE Technician.
nent holster.
2 B/A .5 PSGC/BAOS Check all attachment fittings for ease of operation. Leg strap, center
front buckles
or outer pocket
snaps not able to
fasten securely.
Carabiner
bent/jammed
or not closing
fully EVERY time
pressure is applied
and released.
Pocket zippers not
functioning.
3 B/A .5 Fabric Inspect fabric and webbing for cuts, tears, Fabric cut or torn
and abrasions, fraying and contamination. in excess of 1 inch;
Webbing load webbing cut or
(PSGC/BAOS) torn. (WP 0099 00)
4 B/A .5 Stitching Inspect stitching for breaks, security, and/or loose Any stitch is broken
(PSGC/BAOS) seams. on the load bearing
webbing; more than
8 adjacent stitches
are broken on any
other component.
0091 00-1
0091 00 TM 1-1680-377-13&P-1
5 B .2 Enhanced a. Check antenna for cracks and bends. Ensure Any discrepancies
Mobile it is securely fastened. found refer to TM
Equip- 11-1520-237-23
ment or TM
(EME) 11-1520-240-23.
(PSGC/BAOS)
b. Check for visible cracks in the case.
c. Check all push buttons for function and rubber
covers for rips, tears and cracks.
d. Turn the knurled slotted screw on the back of
the EME and raise the cover.
e. Check battery compartment for cleanliness,
corrosion and security of contacts.
f. Install 3 fully charged AA batteries before each
flight.
g. Ensure battery switch indicates the proper
setting dependent on the type of batteries
installed (Ni-MH or Alkaline).
h. Close the cover and secure the slotted screw.
i. Ensure Jack-Box (J-Box)/Windtalker En-
cryption Device (WED) retaining screws are
secure.
6 B .5 SDU-39/N a. Check flash rate. Turn light on. Count number Light does not
Distress of flashes in a 2-minute duration. Light must operate at 50
Marker operate at 50 flashes per minute 10 flashes. flashes per minute
Light 10 flashes.
(PSGC/BAOS) (WP 0104 00)
b. Check for light leakage. Inspect the SDU-39/N No leakage
in the IR mode for light leakage. Ensure is allowed
housing is closed over light and IR lens cap is (WP 0104 00).
securely attached over lens. In a dark room,
acclimate eyes for a minimum of five minutes.
Turn SDU-39/N on and check for any white
light leakage at all angles.
7 B .1 Flashlight Inspect for signs of damage, cracking, corrosion, Does not illuminate
(PSGC/BAOS) operation and battery leakage. or corrosion
in battery
compartment.
0091 00-2
TM 1-1680-377-13&P-1 0092 00
OPERATOR MAINTENANCE
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
INITIAL SETUP:
Materials/Parts Materials/Parts (cont.)
Detergent, Laundry, Non-Chlorine
Soft Brush (WP 0139 00)
(WP 0139 00, Item 51)
Sponge (WP 0139 00, Item 52) References
Cleaning Cloth (WP 0139 00) WP 0079 00
Lint-Free Cloth (WP 0139 00) WP 0080 00
CLEANING
1. Remove surface dirt using a soft brush or a cloth.
2. Remove all survival items from PSGC.
3. Mix a proper strength solution of non-chlorine detergent following manufacturers instructions or using 1/4 to
1/2 oz. of detergent per gallon of water.
4. Apply cleaning solution to seriously soiled areas with sponge.
5. Allow solution to remain on surface for several minutes, then agitate with soft brush or cloth.
6. Immerse components in solution and allow to soak for five minutes. Agitate gently with hands for two minutes
then remove from solution and allow to drain; do not wring.
7. Rinse components in cool, fresh water until all traces of detergent are gone. Wipe with cloth or sponge, as
necessary.
CAUTION
Do not use dryer or hang in direct sun-light. Do not iron or press. Fire retardant properties
become degraded.
8. Hang on wooden hanger in a well-ventilated area until dry. Drying time may be reduced up by using forced
air (fan) at near-ambient temperature.
9. For rigging and packing GEN I/II PSGC, refer to WP 0079 00.
10. For rigging and packing GEN III PSGC, refer to WP 0080 00.
CHAPTER 15
AVIATION UNIT MAINTENANCE INSTRUCTIONS
FOR
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
CAUTION
Replace equipment when exposed to an aircraft mishap. Replace entire fall arrest system
(including PSGC, ET and PRT) in the event of a fall from the aircraft which induces a dynamic
arrest force.
INTRODUCTION
Preventive Maintenance Checks and Services (PMCS) are performed to keep equipment in operating condition.
Checks are used to find, correct, or report problems. PMCS is done every day equipment is operated.
When performing any PMCS procedure or routine check, observe all safety warnings and cautions.
If your equipment must be in operation at all times, check and service those items that can be checked and serviced
without disturbing operation. Make complete checks and services when equipment can be shut down.
Defects discovered should be corrected as soon as possible. All deficiencies, together with corrective action taken,
should be recorded on forms prescribed for maintenance. See DA PAM 738-751.
PMCS TABLE EXPLANATION
"Item No." Column
This column contains a number for each procedure to be performed. When reporting malfunctions or failures on DA
Form 2408-25, (Mesh Net Survival Vest Inspection Record), place this number in "TM Item No." column.
"Interval" Column
Interval column of your PMCS table tells you when to do a certain check or service. Standard intervals are:
Before - Do before you begin operating equipment or pre-flight.
During - Do while operating equipment.
After - Do after operating equipment.
Periodic - Do once per 180 day interval.
Annual - Do once per 3606 interval.
0093 00-1
0093 00 TM 1-1680-377-13&P-1
NOTE
Terms "ready/available" and "mission capable" refer to same status: equipment is on hand and
is able to perform its combat missions (see AR 700-138).
If you find something wrong and you cant fix it yourself, or you are not authorized to, or you do not have tools, test equip-
ment, parts, documentation, or training to fix it yourself, write it on your DA Form 2408-25, inform your supervisor, and
request assistance.
0093 00-2
TM 1-1680-377-13&P-1 0094 00
INITIAL SETUP:
References References (cont.)
WP 0104 00
WP 0095 00 WP 0200 00
WP 0099 00 WP 0105 00
WP 0128 00 WP 0119 00
WP 0107 00 WP 0116 00
WP 0140 00 TB 9-1300-385
0094 00-1
0094 00 TM 1-1680-377-13&P-1
3 P Stitching Inspect stitching for breaks, security, and/or loose Any stitch is broken
(PSGC/BAOS) seams. on the load bearing
webbing; more than
8 adjacent stitches
are broken on any
other component
(WP 0099 00,
GENERAL
STITCHING
INSTRUCTIONS).
4 P Pockets Inspect pockets and snap fasteners for damage, Pocket cannot
and Snap security, and ease of operation. secure contents;
Fasteners snap fastener
(PSGC/BAOS) broken or fails to
engage/disengage
properly
(WP 0119 00).
5 P Zippers a. Inspect zippers for damage, security, and ease Zippers missing
(PSGC/BAOS) of operation. teeth; slider fails to
engage zipper or
not functioning
properly
(WP 0116 00).
b. Inspect bead slider pulls for presence and Bead slider pull
security of attachment. missing or not
securely attached
(WP 0118 00).
6 P Hook and Inspect hook and pile fastener for damage and Hook and pile
Pile secure closure. fastener fails to
Fastener engage securely
(PSGC/BAOS) (WP 0115 00).
0094 00-2
TM 1-1680-377-13&P-1 0094 00
7 P Hardware Inspect hardware for security, corrosion, dents, Buckle does not
(PSGC/BAOS) burrs, distortion, sharp edges, and ease of securely engage;
operation. buckle does not
easily disengage;
triglide or adjuster
hardware is bent
or jammed; sharp
edge located in
area that could
cut load bearing
webbing; carabiner
not closing fully
EVERY time
pressure is applied
and released;
carabiner bent or
jammed.
8 P Strap Ensure all excess strap material is secured with Strap end keeper
Material Strap End Keeper. missing; hook and
(PSGC/BAOS) pile fastener on
strap end keeper
not closing securely
(WP 0124 00).
9 P Survival Inspect survival items for vacuum seals, missing Vacuum seal
Items items, and serviceable condition. broken or items
(PSGC/BAOS) missing or
unserviceable
(WP 0128 00).
0094 00-3
0094 00 TM 1-1680-377-13&P-1
1 P Survival The service life of the medical items will be Replace expired,
Items ascertained by checking each item for an damaged or
expiration date. The ALSE technician performing missing survival
the inspection should check DOD MEDCAT and items of the PSGC
AR 702-18. These sealed packets are exempt with serviceable
from opening for inspection, but packet may be items from
opened to replace an expired item. stock, refer to
WP 0128 00.
Create medical
packet data card
(WP 0107 00, Step
9.).
0094 00-4
TM 1-1680-377-13&P-1 0094 00
2 P Radio Batteries used with the various types of survival Refer to the
Batteries receiver-transmitters have a service life, which is appropriate
computed from the date of manufacture stamped radio set manual
on each battery. for battery
shelf/service life.
(WP 0140 00
for PRC-90 or
WP 0200 00 for
PRC-112)
5 P Flashlight Inspect light for signs of damage, cracking, Does not illuminate
corrosion, operation and battery leakage. or corrosion
in battery
compartment
(WP 0104 00 and
WP 0105 00).
0094 00-5
0094 00 TM 1-1680-377-13&P-1
6 P Batteries
NOTE
Installed battery life shall be 2 years for survival vest applications. Shelf life shall be 5 years from date
of manufacture, 3 years for AA alkaline batteries.
The L91 Battery is highly recommended for use in all applications since it has up to three times more
energy than the alkaline battery.
0094 00-6
TM 1-1680-377-13&P-1 0094 00
1 B/A/P Distress
Marker
Light
NOTE
The lights shall perform in both lighted areas and in conditions of total darkness.
It is recommended that eyes acclimate in total darkness for a minimum of 5-minutes before performing
IR lens test.
2 P Batteries
NOTE
Installed life shall be 2 years installed life for survival vest applications. Shelf life shall be 5 years from
date of manufacture, 3 years for AA alkaline batteries.
The L91 Battery used in the SDU-39/N is highly recommended for use in all applications since it has
up to three times more energy than the alkaline battery.
4 B/A/P Light Inspect the SDU-39/N in the IR mode for light No leakage
Leakage leakage. Ensure housing is closed over light and is allowed
IR lens cap is securely attached over lens. In a (WP 0104 00).
dark room, acclimate eyes for a minimum of five
minutes. Turn SDU-39/N on and check for any
white light leakage at all angles.
0094 00-7
0094 00 TM 1-1680-377-13&P-1
0094 00-8
TM 1-1680-377-13&P-1 0095 00
INITIAL SETUP:
Personnel Required ALSE Technician/Crew Member
NOTE
Body armor is worn under PSGC. Fitting adjustments will be required when changing configu-
rations.
CROSS POINT OF
RESTRAINT/EXTRACTION
STRAP
MS098804A
0095 00-1
0095 00 TM 1-1680-377-13&P-1
WARNING
All loose straps must be properly secured to eliminate snag hazards. Snag hazards may impede
emergency egress.
5. Roll excess webbing tightly as close to buckles as possible and secure rolls in hook and pile keepers.
MS098757A
6. Adjust shoulder straps, ensuring that top of left and right pockets are horizontal to floor.
7. Middle and lower torso straps must be routed through back loops parallel to floor to avoid creating folds and
bunching of straps.
SHOULDER STRAP
MS098806A
0095 00-2
TM 1-1680-377-13&P-1 0095 00
NOTE
If lower torso strap is below lower edge of soft body armor, jettison of rear ballistic upgrade
plate will be inhibited. If necessary, change middle and lower torso straps to back panel
slots that position webbing above lower edge of soft body armor.
Vest should have a snug but not tight fit. Adjustment of rear torso straps may be required
for comfortable fit. Bottom of vest should rest close to wearers waist when seated.
8. Adjust middle and lower torso straps to fit snugly, ensuring lower torso strap sits above lower edge of body
armor, refer to Figure 4.
MS098807A
9. Adjust back of leg strap assembly so that sub-pelvic strap aligns with lower edge of buttocks, refer to Figure
5.
SUBPELVIC STRAP
MS098808A
10. Secure front leg straps into buckles and cinch webbing to fit securely. Secure loose webbing ends with hook
and pile keepers.
0095 00-3
0095 00 TM 1-1680-377-13&P-1
MS100936A
WARNING
Adjusting PSGC side pockets aft may cause restrictions to arm movement in OH-58D.
15. Non-rated crew members may re-adjust position of gear pockets under arms for comfort and mission re-
quirements.
16. If necessary, re-adjust back leg straps to position sub-pelvic strap connecting webbing with lower edge of
buttocks such that sub-pelvic strap is centered and relatively snug under buttocks.
17. Re-adjust leg straps for snug (not tight) fit. Secure excess webbing with hook and pile keepers.
18. Once all adjustments and attachments are made, instruct aircrew to sit down for a few minutes and then
stand back up. Harness is fit well if there are no pinch points or hot spots. Re-adjust PSGC as necessary for
best fit.
19. Have aircrew remove PSGC.
20. For over-land use, attach extended equipment pouch (EEP) to back of PSGC.
0095 00-4
TM 1-1680-377-13&P-1 0096 00
INITIAL SETUP:
Personnel Required ALSE Technician/Crew Member
NOTE
Body armor is worn under PSGC. Fitting adjustments will be required when changing configu-
rations.
1. Loosen torso, shoulder and leg straps to allow adjustment after donning.
2. Place PSGC on aircrew ensuring cross point of restraint/extraction loop is just above and centered between
wearers shoulder blades.
3. Connect and tighten front buckles on upper and lower torso straps to allow the zipper halves to come together,
refer to Figure 1.
MS100967A
0096 00-1
0096 00 TM 1-1680-377-13&P-1
WARNING
All loose straps must be properly secured to eliminate snag hazards. Snag hazards may impede
emergency egress.
4. Fold excess webbing and secure folds with hook and pile keepers. Secure front zipper, refer to Figure 2.
ZIPPER
MS100968A
Figure 2. Zipper.
5. Adjust shoulder straps evenly, ensuring that top of left and right pockets are horizontal to floor, refer to Figure
3.
SHOULDER STRAP
MS100939A
0096 00-2
TM 1-1680-377-13&P-1 0096 00
6. Middle and lower torso straps must be routed through back loops parallel to floor to avoid creating folds and
bunching of straps.
NOTE
If lower torso strap is below lower edge of soft body armor, jettison of rear ballistic upgrade
plate will be inhibited, which may interfere with water survival. If necessary, raise torso
straps through back panel slots that position webbing above lower edge of ballistic
upgrade plate.
Vest should have a snug but not tight fit. Adjustment of rear torso straps may be required
for comfortable fit. Bottom of vest should rest close to wearers waist when seated.
7. Adjust middle and lower torso straps to fit snugly, ensuring lower torso strap sits above lower edge of ballistic
upgrade plate, refer to Figure 4.
MS100969A
8. Adjust back of leg strap assembly so that sub-pelvic strap aligns with lower edge of buttocks and is horizontal
to floor, refer to Figure 4.
9. Connect leg strap buckles and tighten webbing for a snug fit. Secure loose webbing ends with hook and pile
keepers, refer to Figure 5.
0096 00-3
0096 00 TM 1-1680-377-13&P-1
MS100997A
0096 00-4
TM 1-1680-377-13&P-1 0097 00
INITIAL SETUP:
Personnel Required WP 0094 00
ALSE Technician/Crew Member AR 95-1
References
WARNING
The use of the Hoisting Harness is required in accordance with AR 95-1. Failure to comply
with AR 95-1 will impede the extraction capability of personnel from a combat zone.
When wearing M45 protective mask, pouch for blower motor must be positioned properly
to prevent flight control interference, head and arm movement restrictions, and minimize
field of view restrictions.
All loose straps must be properly secured to eliminate snag hazards. Snag hazards may
impede emergency egress.
NOTE
Before donning and using the BAOS perform PMCS (WP 0094 00).
Equipment pouches may be attached in accordance to the items issued to the individual.
Tourniquet will be placed on the left side shoulder strap.
The extraction strap will be placed on the upper right side of the BAOS main pocket.
If utilizing the utility pouch for first aid items, place the pouch on the left side of the wearer.
The BAOS has a radio pouch, multi-purpose pouch (flashlight/tourniquet), and magazine
pouches that may be used in any combination and position which will not interfere with the
mission.
ASSEMBLY AND PREPARATION FOR USE
NOTE
The BAOS is not recommended to be used with other aircraft platforms.
The Hoisting Harness is not recommended to be used as a retention assembly.
Body Armor Overlay System is worn with the Flexible body armor over the Hoisting
Harness.
Shoulder straps are labeled "L" for left shoulder and "R" for right shoulder.
1. Loosen torso, shoulder and leg straps to allow adjustment after donning.
2. Place Hoisting Harness on crew member ensuring cross point of harness (Figure 1) is just above and
centered between wearers shoulder blades.
0097 00-1
0097 00 TM 1-1680-377-13&P-1
SUBPELVIC
STRAP
MS040399
3. Connect the lifting loops to the carabiner and buckle leg straps (Figure 2) to keep the Hoisting Harness is
place while being adjusted.
0097 00-2
TM 1-1680-377-13&P-1 0097 00
R
L
LEG STRAPS
MS040400
WARNING
Do not place survival items on the back, aligned with the spine of the wearer, this may cause
spinal injuries during a crash sequence.
NOTE
Use all pouches and components from the PSGC to complete the BAOS.
Placement of equipment pouches on the BAOS is user preference, refer to Figure 3.
The first aid platform with contents may be placed in mesh pocket behind the BAOS, or
the first aid items may be placed in a utility pouch (Figure 4).
0097 00-3
0097 00 TM 1-1680-377-13&P-1
MS040477
MESH POCKET
FIRST AID
PLATFORM
MS040401
0097 00-4
TM 1-1680-377-13&P-1 0097 00
LEFT SECURING
SHOULDER
STRAPS
TAB
RIGHT
SHOULDER
TAB
ACTIVITY: 81996
WS8RGZ09D0130
CONTRACT N/O.:
P/N: 10060415
70133
MFR CAGE CODE:
XXXXXXX
NSN: XXXXXX
03/11
LOT NUMBER:
PN:10060405
ON FROM
PROVIDES PROTECTI
ARMOR INSERTS WITH
FLEXIBLE BODY IN ACCORDANCE
9MM, TYPE IIIA WITH
HIGH VELOCITY WHEN WORN
AND NIJ 0101.04.
MILC44050 INSERT, PROVIDES
MILSTD662, PROTECTIVE
D SMALL ARM AP IN
THE ENHAMCE AP, TYPE IV, M2
AGAINST .30 CALIBER 50 AND NIJ 0101.04.
PROTECTION 62, MILC440
WITH MILSTF6
ACCORDANCE
MS040402
ACTIVITY: 81996
CONTRACT N/O.: WS8RGZ09D0130
P/N: 10060415
MFR CAGE CODE: 70133
NSN: XXXXXXXXXXXXX
PROTECTION FROM
FLEXIBLE BODY ARMOR INSERTS PROVIDES
WITH
HIGH VELOCITY 9MM, TYPE IIIA IN ACCORDANCE
WHEN WORN WITH
MILSTD662, MILC44050 AND NIJ 0101.04.
INSERT, PROVIDES
THE ENHAMCED SMALL ARM PROTECTIVE
IV, M2 AP IN
PROTECTION AGAINST .30 CALIBER AP, TYPE
MS040403
0097 00-5
0097 00 TM 1-1680-377-13&P-1
LIFTING LOOPS
MS040404
13. Buckle and adjust torso strap and secure excess strap with hook and pile keeper.
0097 00-6
TM 1-1680-377-13&P-1 0098 00
INITIAL SETUP:
Tools and Special Tools Size E Thread (WP 0139 00, Item 39)
Needle (WP 0133 00, Item 33) Personnel Required
Scissors (WP 0133 00, Item 34) ALSE Technician
Materials/Parts
ADJUSTMENT
MS101008A
0098 00-1
0098 00 TM 1-1680-377-13&P-1
ADJUSTMENT CONTINUED
PSGC BASTING STITCH ADJUSTMENT CONTINUED
2. Reverse direction and secure stitch by placing needle in second yarn from left hand edge (see Figure 2).
MS101009A
3. Then baste top layer of threads across entire width of webbing to right hand edge (see Figure 3).
MS101010A
0098 00-2
TM 1-1680-377-13&P-1 0098 00
ADJUSTMENT CONTINUED
PSGC BASTING STITCH ADJUSTMENT CONTINUED
4. Reverse stitch direction again, starting with second yarn from right-hand webbing edge, and baste back to
midway point (see Figure 4).
MS101011A
5. Secure stitching by running needle through last two stitches made in previous step (see Figure 5). This
buries thread end into webbing.
MS101012A
0098 00-3
0098 00 TM 1-1680-377-13&P-1
ADJUSTMENT CONTINUED
PSGC BASTING STITCH ADJUSTMENT CONTINUED
6. Without knotting thread, cut remaining thread and thread ends (see Figure 6).
MS101013A
0098 00-4
TM 1-1680-377-13&P-1 0099 00
INITIAL SETUP:
Tools and Special Tools Thread, Size E (WP 0139 00, Item 39)
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) Webbing, Nylon Textile (WP 0139 00, Item 25)
Needle, Sewing Machine, Size 20 (WP 0133 00, Item Flame Retardant Textured Nylon Cloth Denier
28) (WP 0139 00, Item 55)
Shears, Tailors (WP 0133 00, Item 13) Oxford Aramid Cloth, Universal Camouflage
Ruler, Wood (WP 0133 00, Item 18) (WP 0139 00, Item 23)
Pencil, China Marking (WP 0133 00, Item 5) References
Cutter, Nylon Webbing (WP 0133 00, Item 1) ASTM-D6193
Materials/Parts FAR Sec 25.853
REPAIR OR REPLACEMENT
WARNING
Never sew PSGC lifting harness. Unauthorized procedures may result in crewmember injury or
death.
1. For repair of material on the PSGC, straight stitching shall be IAW ASTM-D6193, Type 301, 7-11 stitches per
inch using size E thread (WP 0139 00, Item 39), lock stitch 1/2-inch minimum.
2. For double stitching, place stitching 3/16-inches apart centered on binding tape.
3. Using a nylon cutter (WP 0133 00, Item 1), sear cut ends of webbing and tape to prevent fraying. Do not form
sharp edges when doing so.
4. Trim elastic and webbing ends to match edge contour approximately. The trimmed end should remain under
the binding.
5. Using webbing (WP 0139 00, Item 25), tape joints to overlap a minimum of one inch of top layer turned under
and stitched.
6. The basic color of the repair material should match the material being repaired.
7. If substitute webbing and fabrics are used, they must meet flammability requirements of FAR Sec 25.853,
Compartment Interiors.
0099 00-1
0099 00 TM 1-1680-377-13&P-1
WARNING
Never sew PSGC lifting harness. Unauthorized procedures may result in crewmember injury or
death.
NOTE
Worn, torn, or cut areas of material may be patched. If areas are not easily patched, entire
assemblies or subassemblies may need to be replaced.
A hole or tear in a textile component of the Air Warrior Ensemble that exceeds one inch in
length or one inch in diameter should be patched.
The affected area must be located at a point which will allow the finished patch to be
square or rectangular in shape.
The patch should be applied on the outside of the applicable item only.
Do not pin the damaged area.
1. Place the repairable item on a repair table, smooth the fabric around the damaged area, and secure the item
to the table.
2. Using a marking pencil (WP 0133 00, Item 5) and ruler (WP 0133 00, Item 18), mark a square or rectangle
around the area to be patched. Ensure that one side of the marked square or rectangle is parallel to the warp
or filling of the fabric.
3. Using shears (WP 0133 00, Item 13), cut the damaged area fabric along the lines made in Step 1. above.
4. Cut the fabric diagonally at each corner to allow a 1/2-inch foldback in the raw edges.
5. Make a 1/2-inch foldback on each raw edge of material, baste to complete the prepared hole.
6. From patching material, mark and cut a patch 2-1/2 inches wider and longer than the inside measurements
of the prepared hole. Ensure that one side of the patching material is marked and cut along the warp or filling
of the fabric.
7. Center the cut patching material on the prepared hole and ensure the warp or filling of the patch material
matches the warp or filling of the fabric being patched.
8. Make a 1/2-inch fold under each edge of the patching material and baste the patching material to the prepared
area.
9. Secure the repairable item to the repair table. Turn the item over and place a second row of stitching around
the prepared hole, refer to Figure 1.
0099 00-2
TM 1-1680-377-13&P-1 0099 00
OUTSIDE VIEW
INSIDE VIEW
MS100338A
INITIAL SETUP:
Personnel Required References
ALSE Technician WP 0094 00
REPAIR OR REPLACEMENT
PSGC REPLACEMENT
NOTE
Serviceable fittings may be removed and retained as desired.
0100 00-1
0100 00 TM 1-1680-377-13&P-1
Table 1. Primary Survival Gear Carrier (PSGC), Pocket, Content Table. Continued
0100 00-2
TM 1-1680-377-13&P-1 0101 00
PSGC FLASHLIGHT POUCH DISASSEMBLY, INSPECTION, REPLACEMENT AND ASSEMBLY, GEN I/II
AND GEN III
INITIAL SETUP:
Materials/Parts References
Cord, Fibrous, Nylon (WP 0139 00, Item 29) EM 0250 Bowline Video
Personnel Required WP 0094 00
ALSE Technician WP 0129 00
DISASSEMBLY
1. Lay vest on a table, front side up, refer to Figure 1.
NOTE
The flashlight pouch for GEN I/II (Figure 1) is located on and is part the left front outer
pocket.
The multi-purpose pouch (flashlight) for GEN III (Figure 2) may be placed in any combina-
tion or position on the PSGC, which will not interfere with the mission.
0101 00-1
0101 00 TM 1-1680-377-13&P-1
ASSEMBLY CONTINUED
RADIO POUCH
MAGAZINE/AMMO POUCH
FLASHLIGHT POUCH
MS098778B
MS098816B
0101 00-2
TM 1-1680-377-13&P-1 0102 00
PSGC RADIO POUCH DISASSEMBLY, INSPECTION, REPLACEMENT AND ASSEMBLY, GEN I/II AND
GEN III
INITIAL SETUP:
Materials/Parts EM 0250 Bowline Video
Cord, 100 lb. (WP 0139 00, Item 5) WP 0094 00
Cord, Coreless, 100 lb. (WP 0139 00, Item 15) WP 0140 00
WP 0200 00
Personnel Required WP 0129 00
ALSE Technician
References
DISASSEMBLY
1. Lay vest on a table, front side up, refer to Figure 1 for GEN I/II and Figure 2 for GEN III.
MS098779A
0102 00-1
0102 00 TM 1-1680-377-13&P-1
DISASSEMBLY CONTINUED
MS101015A
NOTE
The radio pouch for GEN I/II is located on and is part of the left front pocket outer pocket of
the PSGC.
The radio pouch for GEN III may be placed in any combination or position on the PSGC,
which will not interfere with the mission.
0102 00-2
TM 1-1680-377-13&P-1 0102 00
ASSEMBLY
1. Lay vest on a table, front side up.
NOTE
The radio pouch for GEN I/II is located on left center front pocket of the PSGC.
The radio pouch for GEN III may be placed in any combination or position on the PSGC,
which will not interfere with the mission.
2. Tether survival radio using a 3 ft. length of 100 lb. cord, secured with a bowline (Refer to Bowline Video, EM
0250 or WP 0129 00) knot through grommet on pocket and a bowline (Refer to Bowline Video, EM 0250 or
WP 0129 00) knot tied to attachment fitting on radio.
3. Wind cord around survival radio and place upright into radio pouch.
4. Close and snap radio pouch.
OPERATOR MAINTENANCE
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
INITIAL SETUP:
Materials/Parts Personnel Required
AWIS Enhanced Mobile Equipment (EME) Pouch ALSE Technician/Crew Member
(WP 0135 00, Figure 7, Item 5) References
AWIS Windtalker Encryption Device (WED) ME
WP 0091 00
Pouch (WP 0135 00, Figure 7, Item 2)
DISASSEMBLY
1. Lay vest on a table, front side up.
2. Unsnap the pouch strap.
3. Remove EME.
4. Unsnap and remove pouch from PSGC vest.
INSPECTION-ACCEPTANCE AND REJECTION CRITERIA
Inspect EME for serviceability according to Operator PMCS procedures (WP 0091 00). Replace equipment as re-
quired.
REPAIR OR REPLACEMENT
1. Replace EME if it does not operate or damaged.
2. Replace batteries (WP 0091 00).
ASSEMBLY
1. Lay vest on a table, front side up.
2. Attach pouch to PSGC vest.
3. Place EME in pouch with buttons facing outward.
4. Route pouch strap around antenna and snap. Alternative is to snap strap across top of EME. Refer to Figure
1.
0103 00-1
0103 00 TM 1-1680-377-13&P-1
ASSEMBLY CONTINUED
EME POUCH
STRAP
ANTENNA
ANTENNA
EME POUCH
STRAP
0103 00-2
TM 1-1680-377-13&P-1 0104 00
INITIAL SETUP:
Materials/Parts Materials/Parts (cont.)
Plastic Bag (WP 0139 00, Item 55) Signal Kit, Personnel Distress
Cord, Fibrous, Nylon 100 lb. (WP 0139 00, Item 5) (WP 0135 00, Figure 6, Item 5)
Whistle (WP 0135 00, Figure 6, Item 1) Personnel Required
Compass (WP 0135 00, Figure 6, Item 2) ALSE Technician
Light, Distress Marker (WP 0135 00, Figure 6, Item 3)
References
Mirror, Emergency Signaling
EM 0250 Bowline Video
(WP 0135 00, Figure 6, Item 4)
WP 0094 00
WP 0129 00
DISASSEMBLY
1. Unzip right hand PSGC pocket and remove Signaling Platform from hook and pile.
2. Open Signaling Platform and lay platform as shown in Figure 1.
1 3
MS100210A
3. Remove the Magnetic Lensatic Compass from the upper left pocket of the Signaling Platform and unwind the
cord, refer to Figure 1, Item 6.
4. Untie the bowline knot tied to neck cord of compass, and remove compass.
5. Remove Distress Light Marker from center pocket of Signaling Platform and unwind the cord, refer to Figure
1, Item 3.
0104 00-1
0104 00 TM 1-1680-377-13&P-1
DISASSEMBLY CONTINUED
6. Untie bowline knot tied to neck cord of distress light, remove distress light.
NOTE
Flares and Flare Bandolier make up the Personnel Distress Signal Kit.
7. Remove Personnel Distress Signal Kit from flare pocket/closure pouch and unwind cord, refer to Figure 1,
Item 2.
8. Untie bowline knot in cord at bag and remove flares from plastic bag.
9. Remove 2-inch x 3-inch Emergency Signaling Mirror from elastic keeper on lower left side of platform and
unwind the cord, refer to Figure 1, Item 5.
10. Untie bowline knot at mirror attachment fitting and remove mirror.
11. Remove plastic whistle from right pocket of Signaling Platform and unwind the cord, refer to Figure 1, Item 4.
12. Untie the bowline knot tied to neck cord of whistle and remove whistle.
INSPECTION-ACCEPTANCE AND REJECTION CRITERIA
Once Signaling Platform equipment is removed from platform, inspect equipment for serviceability according to PMCS
procedures (WP 0094 00). Replace equipment as required.
REPAIR OR REPLACEMENT
1. Remove unserviceable Magnetic Lensatic Compass from Signaling Platform according to DISASSEMBLY,
Steps 3. through 4.
2. Tether replacement compass with a 3 ft. length of 100 lb. cord fastened with bowline knots (Refer to Bowline
Video, EM 0250 or WP 0129 00) through a platform grommet and the neck cord of the compass.
3. Remove unserviceable Distress Light Marker from Signaling Platform according to DISASSEMBLY, Steps
5. through 6..
4. When replacing Distress Light Marker, turn the Distress Light Marker ON for 5 to 10 seconds to ensure the
replacement distress light functions, and then turn the light OFF.
5. Tether replacement distress marker with a 3 ft. length of 100 lb. cord fastened with bowline knots (Refer to
Bowline Video, EM 0250 or WP 0129 00) through a platform grommet and the neck cord of the distress light.
NOTE
Flares and Flare Bandolier make up the Personnel Distress Signal Kit.
6. Remove unserviceable Personnel Distress Signal Kit from Signaling Platform according to DISASSEMBLY,
Steps 7. through 8.
7. Place replacement flares in plastic bag and tether launcher for flares with bowline (Refer to Bowline Video,
EM 0250 or WP 0129 00) knot through a small hole cut in bag.
8. Tether flare bandolier with bowline (Refer to Bowline Video, EM 0250 or WP 0129 00) knot at flare bandolier
attachment fitting.
9. Remove unserviceable Emergency Signaling Mirror from Signaling Platform according to DISASSEMBLY,
Steps 9. through 10.
10. Tether replacement signaling mirror with a 3 ft. length of 100 lb. cord fastened with bowline knots (Refer
to Bowline Video, EM 0250 or WP 0129 00) through a platform grommet and the neck cord of the signaling
mirror.
11. Remove unserviceable whistle from Signaling Platform according to DISASSEMBLY, Steps 11. through 12.
0104 00-2
TM 1-1680-377-13&P-1 0104 00
12. Tether replacement whistle with a 3 ft. length of 100 lb. cord fastened with bowline knots (Refer to Bowline
Video, EM 0250 or WP 0129 00) through a platform grommet and the neck cord of the whistle.
ASSEMBLY
1. Lay Signaling Platform as shown in Figure 1.
2. Tether the Magnetic Lensatic Compass with a 3 ft. length of 100 lb. cord fastened with bowline knots (Refer
to Bowline Video, EM 0250 or WP 0129 00) through a platform grommet and the neck cord of the compass.
3. Wind the cord around the compass and place in the upper left pocket of the Signaling Platform, refer to Figure
1, Item 6.
4. Turn the Distress Light Marker ON for 5 to 10 seconds to ensure the light functions, and then turn the light
OFF.
CAUTION
0104 00-3
0104 00 TM 1-1680-377-13&P-1
ASSEMBLY CONTINUED
MS101023A
14. Close right hand PSGC pocket and zip around completely ensuring zipper pulls are placed in a location that
is easily accessible for one-handed operation.
0104 00-4
TM 1-1680-377-13&P-1 0105 00
PSGC SIGNALING PLATFORM DISASSEMBLY, INSPECTION, REPLACEMENT AND ASSEMBLY, GEN III
INITIAL SETUP:
Materials/Parts Materials/Parts (cont.)
Plastic Bag (WP 0139 00, Item 55) Signal Kit, Personnel Distress
Cord, Fibrous, Nylon 100 lb. (WP 0139 00, Item 5) (WP 0135 00, Figure 6, Item 5)
Whistle (WP 0135 00, Figure 6, Item 1) Personnel Required
Compass (WP 0135 00, Figure 6, Item 2) ALSE Technician
Light, Distress Marker (WP 0135 00, Figure 6, Item 3)
References
Mirror, Emergency Signaling
EM 0250 Bowline Video
(WP 0135 00, Figure 6, Item 4)
WP 0129 00
WP 0094 00
DISASSEMBLY
1. Unzip right hand PSGC inner pocket.
2. Unfasten the Signaling Platform from the snap fasteners and lay platform as shown in Figure 1.
3. Remove the Magnetic Lensatic Compass from the lower right hand pocket of the Signaling Platform and
unwind the cord, refer to Figure 1, Item 3.
4. Untie the bowline knot tied to neck cord of compass, and remove compass.
5. Remove Distress Light Marker from center pocket of Signaling Platform and unwind the cord, refer to Figure
1, Item 4.
6. Untie bowline knot tied to neck cord of distress light, remove distress light.
NOTE
Flares and Flare Bandolier make up the Personnel Distress Signal Kit.
7. Remove Personnel Distress Signal Kit located in lower left hand pocket behind the signal mirror, and unwind
cord, refer to Figure 1, Item 6.
8. Untie bowline knot in cord flare bandolier attachment fitting and remove flares from plastic bag.
9. Remove 2-inch x 3-inch Emergency Signaling Mirror from front pocket of Personnel Distress Signal Kit
pocket on lower left side of platform and unwind the cord, refer to Figure 1, Item 5.
10. Untie bowline knot at mirror attachment fitting and remove mirror.
11. Remove plastic whistle from right pocket of Signaling Platform and unwind the cord, refer to Figure 1, Item 2.
12. Untie the bowline knot tied to neck cord of whistle and remove whistle.
0105 00-1
0105 00 TM 1-1680-377-13&P-1
NOTE
Flares and Flare Bandolier make up the Personnel Distress Signal Kit.
6. Remove unserviceable Personnel Distress Signal Kit from Signaling Platform according to DISASSEMBLY,
Steps 7. through 8.
7. Tether the launcher to the bandolier using a bowline (Refer to Bowline Video, EM 0250 or WP 0129 00) knot.
8. Tether flare bandolier with bowline (Refer to Bowline Video, EM 0250 or WP 0129 00) knot at flare bandolier
attachment fitting through a platform grommet.
9. Remove unserviceable Emergency Signaling Mirror from Signaling Platform according to DISASSEMBLY,
Steps 9. through 10.
10. Tether replacement signaling mirror with a 3 ft. length of 100 lb. cord fastened with bowline knots (Refer to
Bowline Video, EM 0250 or WP 0129 00) through a platform grommet and the signaling mirror attachment
fitting.
11. Remove unserviceable whistle from Signaling Platform according to DISASSEMBLY, Steps 11. through 12.
12. Tether replacement whistle with a 3 ft. length of 100 lb. cord fastened with bowline knots (Refer to Bowline
Video, EM 0250 or WP 0129 00) through a platform grommet and the neck cord of the whistle.
ASSEMBLY
1. Lay Signaling Platform as shown in Figure 1.
2. Tether the Magnetic Lensatic Compass with a 3 ft. length of 100 lb. cord fastened with bowline knots (Refer
to Bowline Video, EM 0250 or WP 0129 00) through a platform grommet and the neck cord of the compass.
3. Wind the cord around the compass and place in the lower right pocket of the Signaling Platform, refer to
Figure 1, Item 3.
4. Turn the distress light marker ON for 5 to 10 seconds to ensure the light functions, and then turn the light OFF.
CAUTION
0105 00-2
TM 1-1680-377-13&P-1 0105 00
ASSEMBLY CONTINUED
7. Tether the 2" x 3" Emergency Signaling Mirror with a 3 ft. length of 100 lb. cord fastened with bowline knots
(Refer to Bowline Video, EM 0250 or WP 0129 00) through a platform grommet and the mirror attachment
fitting.
8. Wind cord around mirror and place in front pocket of Personnel Distress Signal Kit pocket on lower left side
of platform, refer to Figure 1, Item 5.
9. Place flares and launcher tethered together in a plastic bag and tether with a bowline knot (Refer to Bowline
Video, EM 0250 or WP 0129 00).
10. Tether the flare bandolier with a 3 ft. length of 100 lb. cord through a small hole cut in bag with bowline (Refer
to Bowline Video, EM 0250 or WP 0129 00)knots through a platform grommet attachment fitting.
11. Wind the cord around the Personal Distress Signal Kit and place both in lower left hand pocket behind the
signal mirror, refer to Figure 1, Item 6.
12. Tether whistle, plastic with 3 ft. length of 100 lb. cord fastened with bowline knots (Refer to Bowline Video,
EM 0250 or WP 0129 00) through a platform grommet, then place in right pocket of platform with open end
toward pocket opening, refer to Figure 1, Item 2.
13. Using pull-the-dot fasteners, attach Signaling Platform to inner right hand pocket.
14. Secure zipper.
2
6
1
3
MIRROR SIGNALING INSTRUCTIONS
E
W
WARNING
DO NOT EXTEND
SHIELD FOR I.R.
OPERATION
MS098817B
4
INITIAL SETUP:
Materials/Parts Personnel Required
Safety Restraint Tether, GEN I/II ALSE Technician
(WP 0135 00, Figure 1, Item 5) References
Safety Restraint Tether, GEN III
(WP 0135 00, Figure 2, Item 7) WP 0094 00
DISASSEMBLY
1. For GEN I/II, unzip left PSGC pocket and remove SRT.
2. For GEN III, unzip left inner PSGC pocket and remove SRT.
INSPECTION-ACCEPTANCE AND REJECTION CRITERIA
1. Inspect SRT (Figure 1) for serviceability according to PMCS procedures (WP 0094 00).
2. If SRT is found unserviceable, discard SRT.
REPAIR OR REPLACEMENT
Replace with new SRT.
ASSEMBLY
1. For GEN I/II, roll SRT loosely to reduce bulk and place in bottom of left PSGC pocket.
2. For GEN III, roll SRT loosely to reduce bulk and place in left inner PSGC pocket or utility pouch.
3. Zip left PSGC pocket closed.
MS098821A
PSGC FIRST AID PLATFORM DISASSEMBLY, INSPECTION, REPLACEMENT AND ASSEMBLY, GEN I/II
AND GEN III
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Shears, Straight Trimmers (WP 0133 00, Item 12)
Punch, Leather (WP 0133 00, Item 14) Combat Trauma Wrap Kit
(WP 0135 00, Figure 5, Item 4)
Materials/Parts Sponge, Rectangular (WP 0135 00, Figure 5, Item 13)
Tape (WP 0135 00, Figure 5, Item 10) Moleskin (WP 0135 00, Figure 5, Item 6)
Povidone-Iodine Topical Solution Eye Pad (WP 0135 00, Figure 5, Item 8)
(WP 0135 00, Figure 5, Item 12) Bandage,Elastic (WP 0135 00, Figure 5, Item 7)
Fire Starter, Aviation Survival, Spark Lite Gloves (WP 0135 00, Figure 5, Item 1)
(WP 0135 00, Figure 5, Item 9) Cord, 100 lb. (WP 0139 00, Item 5)
Bacitracin Ointment (WP 0135 00, Figure 5, Item 14) Plastic Wrap (WP 0139 00, Item 53)
Doxycycline Hyclate (WP 0135 00, Figure 5, Item 2)
Loperamide Capsules (WP 0135 00, Figure 5, Item 3) References
Sunscreen (WP 0135 00, Figure 5, Item 11) WP 0094 00
Acetaminophen Tablets,USP WP 0128 00
(WP 0135 00, Figure 5, Item 15) EM 0250 Bowline Video
Adhesive Bandages (WP 0135 00, Figure 5, Item 5) WP 0129 00
NOTE
The First Aid Platform for PSGC GEN I/II, GEN III and BAOS are disassembled and assembled
in the same manner.
DISASSEMBLY
1. Unzip left hand PSGC pocket and remove First Aid Platform from pocket.
2. Unfasten pull-the-dot or snap fastener to remove platform from extension strap lay platform so snap fasteners
are on left and under platform, refer to Figure 1 for GEN I/II and Figure 2 for GEN III.
0107 00-1
0107 00 TM 1-1680-377-13&P-1
DISASSEMBLY CONTINUED
1
2 3
4
16
5
6
10 7
15 11 8
12 9
13
14
MS100211A
1
2 3 4
16
15
10 5
11 6
12 7
13 8
14 9
MS100214A
3. Remove the vacuum-packed bag containing two pairs of patient exam gloves from top left elastic keeper on
platform and unwind the cord from around bag, refer to Figure 1, Item 16.
4. Untie the bowline knot tied at bag tether tab, and remove bag.
5. Remove the 50-inch roll of 2-inch Duct Tape from top center (left) elastic keeper on platform and unwind the
cord from around bag, refer to Figure 1, Item 2.
6. Remove the vacuum-packed bag containing a 1/2 oz. bottle of Betadine from top center (right) elastic keeper
on platform and unwind the cord from around bag, refer to Figure 1, Item 3.
7. Untie the bowline knot tied at bag tether tab, and remove bag.
8. Remove the vacuum-packed bag containing Aviation Survival Fire Starter from top right elastic keeper on
platform and unwind the cord from around bag, refer to Figure 1, Item 4.
9. Untie the bowline knot tied at bag tether tab, and remove bag.
0107 00-2
TM 1-1680-377-13&P-1 0107 00
DISASSEMBLY CONTINUED
10. Remove the vacuum-packed bag containing 10 Doxycycline Hyclate Capsules, 10 Loperamide HCL Cap-
sules, 10 Acetaminophen Tablets and two tubes of Ophthalmic Bacitracin Ointment, and 3 Sunsect packs
from bottom right two elastic keepers on platform and unwind the cord from around bag, refer to Figure 1,
Item 5-9.
11. Untie the bowline knot tied at bag tether tab, and remove bag.
12. Remove the vacuum-packed bag containing 6 adhesive bandages, a combat trauma wrap kit, a 3.5 x 2.5-inch
expandable sponge, a gauze eye pad, and a 3-inch x 5-inch piece of moleskin from bottom center two elastic
keepers on platform and unwind the cord from around bag, refer to Figure 1, Item 10-14.
13. Untie the bowline knot tied at bag tether tab, and remove bag.
14. Remove the vacuum-packed bag containing elastic bandage from bottom right elastic keepers on platform
and unwind the cord from around bag, refer to Figure 1, Item 5.
15. Untie the bowline knot tied at bag tether tab, and remove bag.
INSPECTION-ACCEPTANCE AND REJECTION CRITERIA
Once First Aid Platform equipment is removed from platform, inspect equipment for serviceability according to PMCS
procedures (WP 0094 00). Replace equipment as required.
Medical item(s) in vacuum-sealed bags are exempt from opening for inspection, but packet may be opened to replace
an expired item.
REPAIR OR REPLACEMENT
1. Remove equipment that has expired according to the disassembly instructions Steps 3. through 15.
2. Open vacuum-packed bag containing expired equipment- remove and discard.
3. Place replacement equipment in new vacuum-seal bag and prepare bag according to WP 0128 00.
ASSEMBLY
1. Lay First Aid Platform so snap fasteners are on left and under platform, refer to Figure 1.
2. Tether a vacuum-packed bag containing two pairs of patient exam gloves to first aid platform with a 3 ft.
length of 100 lb. cord using a bowline (Refer to Bowline Video, EM 0250 or WP 0129 00) knot through bag
tether tab and through a platform grommet.
3. Wind cord around bag and place in top left elastic keeper on platform, refer to Figure 1, Item 16.
4. Place 50-inch roll of 2-inch Duct Tape in top center (left) elastic keeper, refer to Figure 1, Item 2.
5. Tether a vacuum-packed bag containing a 1/2 oz. bottle of Betadine with a 3 ft. length of 100 lb. cord using a
bowline (Refer to Bowline Video, EM 0250 or WP 0129 00) knot through bag tether tab and through a platform
grommet.
6. Wind cord around bag and place in top center (right) elastic keeper next to duct tape on platform, refer to
Figure 1, Item 3.
7. Tether a vacuum-packed bag containing a Aviation Survival Fire Starter with a 3 ft. length of 100 lb. cord
using a bowline (Refer to Bowline Video, EM 0250 or WP 0129 00) knot through bag tether tab and through a
platform grommet.
8. Wind cord around bag and place in top right elastic keeper on platform, refer to Figure 1, Item 4.
0107 00-3
0107 00 TM 1-1680-377-13&P-1
ASSEMBLY CONTINUED
9. In medical packet containing Doxycycline Hyclate Capsules, Loperamide HCL Capsules, Acetaminophen
Tablets and two tubes of Ophthalmic Bacitracin Ointment and Sunsect packs insert a 2-inch by 3.5-inch
card/paper on clear side of packet containing the Expiration dates and Lot numbers of the items with expira-
tion date. See sample below.
10. Tether a vacuum-packed bag containing 10 Doxycycline Hyclate Capsules, 10 Loperamide HCL Capsules,
10 Acetaminophen Tablets and two tubes of Ophthalmic Bacitracin Ointment and 3 Sunsect packs with a 3
ft. length of 100 lb. cord using a bowline (Refer to Bowline Video, EM 0250 or WP 0129 00) knot through bag
tether tab and through a platform grommet.
11. Wind cord around bag and place in bottom right elastic keeper on platform, refer to Figure 1, Item 5-9.
12. Tether a plastic vacuum-packed bag containing 6 adhesive bandages, a combat trauma wrap kit, a 3.5-inch
x 2.5-inch expandable sponge, a gauze eyepad, and a 3-inch x 5-inch piece of moleskin with a 3 ft. length of
100 lb. cord using a bowline (Refer to Bowline Video, EM 0250 or WP 0129 00) knot through bag tether tab
and through a platform grommet.
13. Wind cord around bag and place in bottom center elastic keepers on platform, refer to Figure 1, Item 10-14.
14. Tether a plastic vacuum-packed bag containing a elastic bandage with a 3 ft. length of 100 lb. cord using a
bowline (Refer to Bowline Video, EM 0250 or WP 0129 00) knot through bag tether tab and through a platform
grommet.
15. Wind cord around bag and place in bottom left elastic keepers on platform, refer to Figure 1, Item 15.
NOTE
The first aid platform for the BAOS may be placed in mesh pocket on backside of BAOS, or the
first aid items may be placed in a utility pouch.
16. Attach First Aid Platform to left pocket extension strap with snaps.
17. Insert platform into pocket so that platform lays flat in pocket.
18. Zip pocket closed.
0107 00-4
TM 1-1680-377-13&P-1 0108 00
INITIAL SETUP:
Materials/Parts Materials/Parts (cont.)
Drinking Water Bag (WP 0135 00, Figure 4, Item 2) Gauze Bandage (WP 0135 00, Figure 4, Item 11)
Blanket, Casualty (WP 0135 00, Figure 4, Item 5) Sunscreen (WP 0135 00, Figure 4, Item 1)
Water, Drinking Packet (WP 0135 00, Figure 4, Item 8)
Ration Candy (WP 0135 00, Figure 4, Item 10) Personnel Required
Water Purification (WP 0135 00, Figure 4, Item 3) ALSE Technician
Cord, 550 lb (WP 0135 00, Figure 4, Item 7) References
Fire Starter, Spark-Lite (WP 0135 00, Figure 4, Item 6) WP 0094 00
Plastic Freezer Bags (WP 0135 00, Figure 4, Item 4) WP 0128 00
DISASSEMBLY
1. Unsnap two snaps holding EEP to PSGC. These are unmarked pull-the-dot fasteners and must be pulled
from bottom edge of EEP, see Figure 1.
MS038564
0108 00-1
0108 00 TM 1-1680-377-13&P-1
DISASSEMBLY CONTINUED
NOTE
The EEP can be mounted on either side of the PSGC, behind the right or left pocket and along
the harness torso straps.
0108 00-2
TM 1-1680-377-13&P-1 0109 00
LEFT AND RIGHT FRONT PSGC POCKETS, REMOVE AND REPLACEMENT, GEN I/II
INITIAL SETUP:
Personnel Required ALSE Technician
NOTE
PSGC is serviceable if pockets have two zipper sliders. Close pocket and zip completely
ensuring zipper pulls are placed in a location easily accessible for one-handed operation.
REMOVAL
1. Unzip pocket so that both sliders are at zipper stops.
2. Remove outer slider by removing free pin.
3. Slide slider off of open zipper ends.
REPAIR OR REPLACEMENT
1. Lay PSGC on table, pocket side up.
2. Slide zipper pulls against stops, lay outer half of pocket on PSGC ensuring it is positioned properly.
3. Start with inner portion of zipper, carefully insert open end into slider throat and slide zipper slider up tape to
catch teeth.
4. Repeat Step 3. for outer zipper slide.
PSGC TOURNIQUET POUCH DISASSEMBLY, INSPECTION, REPLACEMENT AND ASSEMBLY, GEN I/II
AND GEN III
INITIAL SETUP:
Materials/Parts Personnel Required
Tourniquet (WP 0135 00, Figure 7, Item 7) ALSE Technician
Tourniquet Pouch (WP 0135 00, Figure 1, Item 13) References
Tourniquet Pouch (WP 0135 00, Figure 2, Item 12) WP 0094 00
DISASSEMBLY
1. Lay vest on a table, front side up.
2. Unsnap tourniquet pouch (Figure 1) and remove tourniquet.
3. Unsnap and remove tourniquet pouch from PSGC vest.
INSPECTION-ACCEPTANCE AND REJECTION CRITERIA
Inspect tourniquet for serviceability according to PMCS procedures (WP 0094 00).
REPAIR OR REPLACEMENT
If tourniquet is unserviceable, replace tourniquet, refer to ASSEMBLY, Step 3.
ASSEMBLY
1. Lay vest on a table, front side up.
2. Attach tourniquet pouch to left shoulder strap of the PSGC vest.
3. Unsnap pouch and place tourniquet in pouch.
4. Close and snap pouch.
MS098748A
INITIAL SETUP:
Personnel Required References
ALSE Technician EM 0250 Adapter Platform Video
INSTALLATION
See Adapter Platform Video, EM 0250.
NOTE
Adapter platform may be installed on the left or the right side of the PSGC and one or two may
be installed depending on the comfort of the wearer. Is best if the panel is installed level with the
vest pocket.
1. Loop adapter platform thru the last column of the PSGC main pocket.
2. Loop remaining straps thru the upper and lower torso straps.
3. Secure in place with snaps.
MS098734A
FIRST AID PLATFORM LH POCKET EXTENSION REPLACEMENT, GEN I/II AND GEN III
INITIAL SETUP:
Tools and Special Tools Thread, Size E (WP 0139 00, Item 39)
Cutter, Nylon Webbing (WP 0133 00, Item 1) Socket, Snap Fastener (WP 0139 00, Item 31)
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) Cap, Snap Fastener (WP 0139 00, Item 32)
Needle, Sewing Machine, Size 20 (WP 0133 00, Item Webbing, 1 1/2-inch (WP 0139 00, Item 47)
28) Personnel Required
Materials/Parts ALSE Technician
REPAIR OR REPLACEMENT
1. Remove damaged pocket extension by cutting/searing 2-inches from point of attachment to PSGC. This
leaves an attachment tab for application of new extension. If made of aramid cloth, cut fabric as close as
possible from edge binding.
2. Using a nylon webbing cutter, cut/sear 18-inches of 1 1/2-inch webbing.
3. Make a 2 1/2-inch fold on one end of webbing and using sewing machine, make a box stitch.
4. Install a snap fastener socket and cap centered on box stitch facing wearer when vest is worn.
5. Place repair webbing onto attachment tab with a 1 1/2-inch overlap and sew a box stitch.
6. If aramid cloth was removed, align repair webbing with edge binding and stitch in place with three rows of
stitches being careful not to damage zipper.
PSGC FIRST AID PLATFORM ELASTIC KEEPER REPLACEMENT, GEN I/II AND GEN III
INITIAL SETUP:
Tools and Special Tools Materials/Parts
China Marker (WP 0133 00, Item 5) Elastic Webbing, 1-inch wide (WP 0139 00, Item 28)
Razor, Surgical Preparation (WP 0133 00, Item 8) Thread, Size E (WP 0139 00, Item 39)
Shears, Tailors (WP 0133 00, Item 13) Personnel Required
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) ALSE Technician
REPAIR OR REPLACEMENT
1. Using shears, cut a length of elastic webbing equal in length to damaged elastic strip.
2. If applicable, mark new elastic with locations of bartacks with China marker.
3. Carefully unstitch binding with surgical preparation razor, ensuring that binding is not cut. Loosen enough
binding to remove damaged elastic.
4. If applicable, cut bartacks to remove damaged elastic. Remove loose threads.
5. Place new elastic according to previous China marker markings.
6. Using sewing machine and size E thread, stitch ends with three rows of straight stitching, making sure not to
catch binding in this stitching.
7. If applicable, sew three rows of stitching at bartack locations.
8. Tuck ends of elastic inside unstitched binding; stitch 1/8-inch from each side of binding, backstitching
1/2-inch at start and end of stitching.
INITIAL SETUP:
Tools and Special Tools Webbing, Nylon, Textile, Type III
Razor (WP 0133 00, Item 8) (WP 0139 00, Item 18)
Shears, Tailors (WP 0133 00, Item 13) Thread, Size E (WP 0139 00, Item 39)
Sewing Machine, Med. Wt (WP 0133 00, Item 9) Personnel Required
Needle, Sewing Machine, Size 20 (WP 0133 00, Item ALSE Technician
28) References
Materials/Parts FM 10-16
REPAIR OR REPLACEMENT
1. If required, trim away shredded or damaged binding.
2. Using shears, cut a strip of webbing 3-inches longer than edge to be repaired.
3. Fold under 1/2-inch on each end of webbing to prevent ends from unraveling.
4. Fold webbing lengthwise and place it over damaged area overlapping the webbing 1-inch on each side.
5. Using a sewing machine, size 20 needle, and size E thread, stitch length of webbing maintaining a distance
of 1/4-inch from folded edge.
6. Stitch 1/8-inch from folded edge, backstitching 1/2-inch at both beginning and end of stitch line.
7. Stitch 1/8-inch from webbing edge, backstitching 1/2-inch at both beginning and end of stitch line.
8. Another row of stitching may be added 1/8-inch from folded edge of webbing for appearance.
INITIAL SETUP:
Tools and Special Tools Materials/Parts
China Marker (WP 0133 00, Item 5) Hook and Pile Fastener Tape (WP 0139 00, Item 11)
Razor (WP 0133 00, Item 8) Thread, Size E (WP 0139 00, Item 39)
Shears, Tailors (WP 0133 00, Item 13) Personnel Required
Sewing Machine, Med. Wt. (WP 0133 00, Item 9)
ALSE Technician
Needle, Sewing Machine, Size 20 (WP 0133 00, Item
28)
REPAIR OR REPLACEMENT
1. With China marker, mark location of hook and pile fastener tape.
2. Cut stitches with razor to remove damaged hook and pile fastener tape. If edges are secured in binding,
carefully unstitch enough binding to loosen fastener tape.
3. Using damaged hook and pile fastener tape as a guide, cut a new length of fastener tape.
4. Place hook and pile fastener tape on marked area from Step 1.
5. Using size E thread, stitch along both edges of hook and pile fastener tape.
6. If applicable, tuck ends of fastener tape under binding and restitch binding.
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Pencil, China Marker (WP 0133 00, Item 5) Zipper (WP 0139 00, Item 48)
Razor (WP 0133 00, Item 8) Thread, Size E (WP 0139 00, Item 39)
Clamp, Spring, Small (WP 0133 00, Item 31) Personnel Required
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) ALSE Technician
REMOVAL
NOTE
On left or right side of harness, PSGC pocket zipper is attached to a webbing repair strip.
This webbing strip remains on harness to allow replacement of zipper without stitching on
load-bearing webbing.
Stitching on load-bearing webbing is NOT authorized for any repair.
1. With a China marker, mark beginning and end of zipper box and pin ends. Note orientation of overlap of box
and pin ends.
2. Using razor, remove damaged zipper half, making sure not to damage zipper repair strip. Remove all loose
thread ends.
REPAIR OR REPLACEMENT
NOTE
If original location and orientation of zipper box and pin ends are not maintained, zipper will not
mate to pocket zipper properly.
1. Secure new zipper half to zipper repair strip, using small clamps to align with China marker lines and to
ensure even placement along zipper repair strip.
2. Using sewing machine, stitch zipper to zipper repair strip 1/8-inch from zipper tape edge. Back stitch at least
1/2-inch to secure stitch end.
POCKET PULL TABS, REPAIR AND REPLACEMENT, GEN I/II AND GEN III
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Cutter, Nylon Webbing (WP 0133 00, Item 1)
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) Stud (WP 0139 00, Item 28)
Razor, Surgical Preparation (WP 0133 00, Item 8) Socket (WP 0139 00, Item 31)
Nippers, End Cutting (WP 0133 00, Item 4) Button (WP 0139 00, Item 32)
Eyelet (WP 0139 00, Item 33)
Materials/Parts
Webbing, Nylon Textile (WP 0139 00, Item 55) Personnel Required
Thread, Size E (WP 0139 00, Item 39) ALSE Technician
REPAIR OR REPLACEMENT
NOTE
Same procedure is used to replace all pocket pull tabs.
1. Carefully cut stitching holding pull tab webbing to pocket using a surgical preparation razor.
2. Remove underside of snap fastener using end-cutting nippers. Remove top and bottom of snap fastener
from pocket.
3. Using nylon webbing cutter, cut and sear a 4.75-inch length of 1-inch webbing.
4. Fold 1-inch of webbing on itself and using sewing machine, box stitch edges using size E thread.
5. Lay free end of webbing on underside of pocket flap in same position as original webbing.
6. Attach webbing to flap with a box stitch using size E thread.
7. Install button and eyelet in original position on pocket, through new webbing, using a snap fastener press.
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Cutter, Nylon Webbing (WP 0133 00, Item 1)
Razor, Surgical Preparation (WP 0133 00, Item 8)
Cord, Coreless (WP 0139 00, Item 26)
Materials/Parts
Webbing, Elastic, 1-inch (WP 0139 00, Item 18) Personnel Required
Thread, Size E (WP 0139 00, Item 51) ALSE Technician
REPAIR OR REPLACEMENT
1. Cut existing bead slider pull webbing if attached and discard. Bead may be reused.
2. Using a nylon cutter, cut and sear an 8-inch length of coreless cord.
3. Loop cord through zipper pull tab, refer to Figure 1.
4. Fold cord in half and slide bead onto cord against pull tab.
5. Tie a binder knot to secure bead.
6. Cut and sear excess cord.
MS098727A
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Nippers, End Cutting (WP 0133 00, Item 4)
Press, Hand, Chuck & Die, M369 and M370 Eyelet (WP 0139 00, Item 36)
(WP 0133 00, Item 6) Cap (WP 0139 00, Item 37)
Materials/Parts Stud (WP 0139 00, Item 38)
Stud (WP 0139 00, Item 30) Personnel Required
Socket (WP 0139 00, Item 31) ALSE Technician
Cap (WP 0139 00, Item 32)
Eyelet (WP 0139 00, Item 33) References
Socket (WP 0139 00, Item 35) WP 0099 00
REPAIR OR REPLACEMENT
Repair a loose snap fastener by reseating fastener on a hand or foot-operated press as follows:
1. Install an applicable size chuck and die on press.
2. Snap fastener socket or stud, refer to Figure 1, as applicable, in chuck. Position fastener cap or post, as
applicable on die.
3. Depress press handle or lever to seat socket and cap or stud and eyelet, as applicable.
4. Check fastener for firm seating. If required, repeat procedure in Step 3. above. Ensure socket snaps on and
off stud without hindrance.
NOTE
A snap, fastener which is defective or cannot be reseated shall be replaced with a serviceable
item from stock. However, if only one part of fastener is defective (such as socket assembly or
stud assembly) just that particular assembly will need to be replaced.
Remove and replace a damaged snap fastener as follows:
1. Using nippers, remove original snap fastener.
2. If necessary, repair fabric area around fastener, refer to WP 0099 00, GENERAL PATCHING
INSTRUCTIONS.
3. Install replacement fastener or fastener part assembly using procedures in REPAIR OR REPLACEMENT
above.
4. Place hole cut in fabric over stem of cap or stud prior to actuating press.
0119 00-1
0119 00 TM 1-1680-377-13&P-1
SOCKET
ASSEMBLY
CHUCK MATERIAL
CAP
SOCKET
DIE
STUD
CHUCK ASSEMBLY
MATERIAL
POST
STUD DIE
MS100938A
0119 00-2
TM 1-1680-377-13&P-1 0120 00
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Razor, Surgical Preparation (WP 0133 00, Item 8) Grommet (WP 0139 00, Item 7)
Nippers, End Cutting (WP 0133 00, Item 4) Grommet (WP 0139 00, Item 34)
Punch and Die, Grommet Inserting (WP 0133 00, Personnel Required
Item 7)
ALSE Technician
Punch, Leather (WP 0133 00, Item 14)
Mallet, Rawhide (WP 0133 00, Item 17)
REPAIR OR REPLACEMENT
Replace a defective eyelet grommet and washer with serviceable items of same size from stock and follow procedures
below:
1. Using cutting nippers, cut crimped edge of original grommet at three or four points.
2. Pry cut crimped edges back and remove original grommet and washer.
3. Using a grommet hole cutter, cut a suitable sized hole in reinforcement material to accommodate applicable
size grommet. Ensure hole is cut with a slightly smaller diameter than diameter of replacement grommet
barrel.
4. Insert barrel of replacement grommet or through hole cut in Step 3. above.
5. Ensure grommet flange is located on same side of webbing as original grommet.
6. Position grommet on a comparable sized die with barrel facing up and place washer over grommet barrel,
refer to Figure 1.
7. Using a punch and mallet, spread grommet barrel by hammering until barrel collar is flattened and rolled
down smooth on washer.
8. Check seating of grommet. If grommet can be turned by hand, repeat procedure in Step 7. until grommet is
firmly seated.
0120 00-1
0120 00 TM 1-1680-377-13&P-1
MALLET
PUNCH
WASHER
MATERIAL
GROMMET BARREL
GROMMET
DIE
MS100937A
0120 00-2
TM 1-1680-377-13&P-1 0121 00
INITIAL SETUP:
Tools and Special Tools Webbing, 1-inch (WP 0139 00, Item 17)
Cutter, Nylon Webbing (WP 0133 00, Item 1) Grommet (WP 0139 00, Item 34)
China Marker (WP 0133 00, Item 5) Thread, Size E (WP 0139 00, Item 39)
Razor (WP 0133 00, Item 8) Personnel Required
Shears, Tailors (WP 0133 00, Item 13) ALSE Technician
Sewing Machine, Med. Wt. (WP 0133 00, Item 9)
References
Needle, Sewing Machine, Size 20 (WP 0133 00, Item
28) WP 0120 00
Materials/Parts
REPAIR OR REPLACEMENT
1. With China marker, mark location of damaged 4-Grommet Tab.
2. Using razor, cut stitches to remove damaged 4-Grommet Tab.
3. Using shears, cut a 2-inch length of 1-inch webbing. Using a nylon cutter, sear ends.
4. Using damaged 4-Grommet Tab as a pattern, mark locations for 4 grommets.
5. Replace with 4 new grommets, refer to WP 0120 00. Ensure that grommets are placed close to one edge of
strip to allow room for stitching.
6. Place new 4-Grommet Tab in location marked in Step 1.
7. Using size 20 needle and size E thread, stitch in place, back stitching both ends 1/2-inch.
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Cutter, Nylon Webbing (WP 0133 00, Item 1)
Shears, Tailors (WP 0133 00, Item 13) Stud (WP 0139 00, Item 30)
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) Eyelet (WP 0139 00, Item 33)
Materials/Parts Personnel Required
Webbing, 1-inch (WP 0139 00, Item 17)
ALSE Technician
Cap (WP 0139 00, Item 32)
Socket (WP 0139 00, Item 31) References
Thread, Size E (WP 0139 00, Item 39) WP 0119 00
REPAIR OR REPLACEMENT
1. Remove damaged connector strap by cutting 1 1/2-inch from attachment point to EEP, refer to Figure 1.
2. Remove piece of webbing not attached to EEP. This forms an attachment tab for new connector strap.
3. Using nylon webbing cutter, sear end of attachment tab.
4. Using shears, cut a length of webbing 28-inches long. Sear cut ends with nylon webbing cutter.
5. Fold webbing in half and position cut ends over attachment tab with cut ends of webbing about 1/8-inch from
attachment point.
6. Using sewing machine and size E thread, stitch a box that is 1/8-inch from webbing edges and 1-inch long.
7. Stitch another box that is 1/8-inch from webbing edges and starts about 1/8-inch from end of previous box
and ends 1/8-inch from folded edge.
8. Install cap and socket (WP 0119 00), centered 1 1/4-inches from folded edge of webbing making sure that
button is on corresponding side of strap as it is on EEP strap and can be snapped onto EEP, refer to Figure 1.
1 IN
EEP 1 IN
1 IN
MS100982A
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)
Cutter, Nylon Webbing (WP 0133 00, Item 1)
Shears, Tailors (WP 0133 00, Item 13)
China Marker (WP 0133 00, Item 5) Cap (WP 0139 00, Item 32)
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) Socket (WP 0139 00, Item 31)
Needle, Size 20 (WP 0133 00, Item 28) Personnel Required
Materials/Parts ALSE Technician
Thread, Size E (WP 0139 00, Item 39)
Webbing, Textile, Nylon Type, 1-inch References
(WP 0139 00, Item 25) WP 0119 00
REPAIR OR REPLACEMENT
1. Remove damaged connector strap by cutting 1-inch from attachment point.
2. Remove piece of webbing not attached. This forms an attachment tab for new connector strap.
3. Using nylon webbing cutter, sear end of attachment tab.
4. Using shears, cut a length of webbing double the length of cut piece. Sear cut ends with nylon webbing cutter.
5. Fold webbing in half and position cut ends over attachment tab with cut ends of webbing about 1/8-inch from
attachment point.
6. Using sewing machine and size E thread, stitch a box that is 1/8-inch from webbing edges and 3/4-inch long.
7. Stitch another box that is 1/8-inch from webbing edges and starts about 1/8-inch from end of previous box
and ends 1/8-inch from folded edge.
8. Install cap and socket (WP 0119 00), centered 3/4-inches from folded edge of webbing making sure that
button is on corresponding side of strap as it is on pouch strap and can be snapped onto pouch.
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Cutter, Nylon Webbing (WP 0133 00, Item 1) Webbing, 1-inch (WP 0139 00, Item 28)
Shears, Tailors (WP 0133 00, Item 13) Hook and Pile Fastener Tape (WP 0139 00, Item 11)
Razor (WP 0133 00, Item 8) Thread, Size E (WP 0139 00, Item 39)
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) Personnel Required
Needle, Sewing Machine, Size 20 (WP 0133 00, Item
ALSE Technician
28)
REPAIR OR REPLACEMENT
1. Using shears, cut a piece of webbing 6-inches long; using a nylon cutter, sear ends.
2. Using shears, cut a piece of hook and a piece of pile fastener tape, 1 3/4-inches long each.
3. Align hook fastener tape with one end of webbing, and stitch all around tape using sewing machine and size
E thread.
4. Turn webbing over, and align pile fastener tape on opposite end of webbing; stitch all around tape.
5. With a razor, cut stitches to remove damaged strap end keeper from PSGC, noting orientation of hook and
pile in relation to harness webbing.
6. Attach new strap end keeper by placing it at end of harness webbing and stitching in place with a box stitch.
INITIAL SETUP:
Tools and Special Tools Webbing, Elastic, 1-in (WP 0139 00, Item 28)
Cutter, Nylon Webbing (WP 0133 00, Item 1) Fastener, Hook and Pile (WP 0139 00, Item 11)
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) Webbing, Elastic, 1.75-in (WP 0139 00, Item 28)
Shears (WP 0133 00, Item 12) Thread, Size E (WP 0139 00, Item 39)
Needle, Sewing Machine, Size 20 (WP 0133 00, Item Buckle, Quick Release Adjustable
28) (WP 0139 00, Item 20)
Materials/Parts
REPAIR OR REPLACEMENT
NOTE
Only section extending from PSGC is authorized for repair.
Repair is possible only if damaged area is 2-inches or more from PSGC.
Right torso strap assembly is not repairable.
1. Using shears, cut webbing 2 to 3-inches from PSGC. Retain serviceable buckle for reuse. Discard unser-
viceable buckle and webbing.
2. Using a nylon cutter, cut and sear a 5 3/4-inch length of 1-inch webbing.
3. Cut and sear a 1 3/4-inch length of 1-inch hook fastener.
4. Cut and sear a 1 3/4-inch length of 1-inch pile fastener.
5. Attach hook fastener and pile fastener to ends of 1-inch webbing as shown using a box stitch and size E
thread.
6. Using a nylon cutter, cut and sear a 34-inch length of 1 3/4-inch webbing.
7. Fold 1 1/2-inches of end of webbing over on itself and stitch with a bar stitch using size E thread.
8. Attach 5 3/4-inch webbing sections to end of folded end of 34-inch webbing 3/4-inch from end of webbing fold
using a box stitch and size E thread.
9. Place free end of 34-inch webbing over original 2 to 3-inch PSGC torso strap stub with a 2-inch overlap and
secure two sections together with a box-X stitch using size E thread.
INITIAL SETUP:
Materials/Parts ALSE Technician
Leg Straps Regular or Long References
(WP 0135 00, Figure 2, Item 8) WP 0095 00
Personnel Required
REMOVAL
Remove left and right leg straps from PSGC by unweaving straps from tri-glide fittings.
REPAIR OR REPLACEMENT
1. Weave straps through tri-glides.
2. Adjust leg strap assembly for proper fit, refer to WP 0095 00, Steps 9. through 10.
INITIAL SETUP:
Tools and Special Tools Thread, Size E (WP 0139 00, Item 39)
Cutter, Nylon Webbing (WP 0133 00, Item 1) Nylon Tape, 3/4 Inch Wide (WP 0139 00, Item 19)
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) Personnel Required
Shears (WP 0133 00, Item 12) ALSE Technician
Materials/Parts
REPAIR OR REPLACEMENT
1. Using a nylon cutter, cut and sear a 4-inch length of 3/4-inch nylon tape, refer to Figure 1, Detail A.
2. Fold in half lengthwise and stitch 1/8-inch from the open tape edge with E thread, refer to Figure 1, Detail A.
3. Place bottom of tape 1-inch from the top edge of the pad as shown. On one side stitch two rows following
the stitch pattern around the pad edge binding, backstitch each end with size E thread as shown in Figure 1,
Detail B.
4. Insert 3/4-inch nylon tape through leg strap, refer to Figure 1, Detail C.
5. On the remaining open 3/4-inch tape edge, stich two rows following the stitch pattern around the pad edge
binding, backstitch each end with size E thread as shown in Figure 1, Detail D.
0127 00-1
0127 00 TM 1-1680-377-13&P-1
1" STITCH
DETAIL B
1"
1/8"
FOLD TAPE
DETAIL A DETAIL D
STITCH 1/8" STITCH
FROM EDGE
4"
LEG
STRAP
PAD
BUCKLE
MS100113A
0127 00-2
TM 1-1680-377-13&P-1 0128 00
INITIAL SETUP:
Tools and Special Tools Plastic Wrap (WP 0139 00, Item 53)
Sealing Iron, Electric (WP 0133 00, Item 30) Plastic Wrap (WP 0139 00, Item 54)
Shears, Tailors (WP 0133 00, Item 13) Plastic Bag (WP 0139 00, Item 55)
Punch (WP 0133 00, Item 26) Personnel Required
Materials/Parts ALSE Technician
ASSEMBLY
1. Using shears, cut a 3 x 5 piece of plastic wrap to create bags for first aid items. To create bag for other
equipment cut plastic wrap 1" larger than equipment to be packed.
2. Using the sealing iron, seal three sides of the plastic wrap, insert equipment.
3. Vacuum seal remaining side of bag.
4. Using a single punch, punch a hole in side of bag for tethering tab.
WARNING
Each vacuum packed bag must have a tear strip on all 4 sides to aid in opening by injured
aircrew.
5. Using shears, cut a tear strip on all four sides of bag toward the center of the vacuum bag.
INITIAL SETUP:
Personnel Required ALSE Technician
ASSEMBLY
NOTE
End B of cord is already attached to an eyelet.
B B
B
B
B
A
A
A
A
MS040280
INITIAL SETUP:
Tools and Special Tools Materials/Parts
Sewing Machine, Med. Wt. (WP 0133 00, Item 9) Ring Strap (WP 0139 00, Item 56)
Needle, Size 20 (WP 0133 00, Item 28) Thread, Size E (WP 0139 00, Item 39)
China Marker (WP 0133 00, Item 5) Personnel Required
Shears, Straight Trimmers (WP 0133 00, Item 12) ALSE Technician
PURPOSE OF MODIFICATION
To install Ring Strap on the PSGC GEN II and GEN III providing an attachment point for the cinching strap of the Air War-
rior Flotation Collar Assembly.
REPAIR OR REPLACEMENT
0130 00-1
0130 00 TM 1-1680-377-13&P-1
NOTE
When sewing the center reference mark and the reference mark on the male snap end, ensure
that the zipper is not in the path of the needle of the sewing machine. Sewing machine may
break zipper.
8 7 6 5 4 3 2 1
1/8
1 3/4
3 5/8
MS098726A
Figure 1. Measure.
MS098805A
0130 00-2
TM 1-1680-377-13&P-1
CHAPTER 16
SUPPORTING INFORMATION
FOR
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
SUPPORTING INFORMATION
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
REFERENCES
SCOPE
This section lists all forms and publications referenced in this manual and required by the user to maintain the PSGC.
AMERICAN NATIONAL STANDARDS INSTITUTE
ANSI Z359.1 American National Standard Safety Requirements for Personal
Fall Arrest System, Subsystems and Components
ARMY REGULATIONS
AR 700-138 Army Logistics Readiness and Sustainability
AR 702-18 Materiel Quality Storage Standards Policy for Shelf-Life Materiel
AR 710-2 Supply Policy Below the National Level
COMMON TABLES OF ALLOWANCE (CTA)
CTA 50-970 Expendable/Durable Items (Except Medical,
Class V, Repair Parts, and Heraldic Items)
CTA 8-100 Army Medical Department Expendable/Durable Items
DEPARTMENT OF THE ARMY FORMS (DA)
DA Form 2408-25 Mesh Net Survival Vest Inspection Record
DEPARTMENT OF THE ARMY PAMPHLETS (DA PAM)
DA PAM 710-2-2 Supply Support Activity System: Manual Procedures
DA PAM 738-751 Functional Users Manual for the Army Maintenance
Management System - Aviation (TAMMS-A)
DA PAM 750-8 The Army Maintenance Management System (TAMMS) Users Manual
DEPARTMENT OF DEFENSE FORMS (DD)
DD Form 1574 Serviceable Tag- Materiel
FIELD MANUALS(FM)
FM 10-16 General Fabric Repair
STANDARD FORMS (SF)
SF 368 Product Quality Deficiency Report
TECHNICAL BULLETINS (TB)
TB 9-1300-385 Munitions Restricted or Suspended
TB 43-0108 Handling, Storage and Disposal of Army Aircraft
Components Containing Radioactive Materials
TB 43-180 Interactive Electronic Technical Manual for Calibration and Repair
Requirements for The Maintenance of Army Materiel
TECHNICAL MANUALS (TM)
TM 1-1500-204-23 (Series) Aviation Unit Maintenance (AVUM) and Aviation Intermediate Mainte-
nance (AVIM) Manual for General Aircraft Maintenance
0131 00-1
0131 00 TM 1-1680-377-13&P-1
0131 00-2
TM 1-1680-377-13&P-1 0132 00
SUPPORTING INFORMATION
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
INTRODUCTION MAINTENANCE ALLOCATION CHART (MAC)
INTRODUCTION
Aviation Maintenance Allocation Chart
The MAC (immediately following the introduction) designates overall authority and responsibility for the performance
of maintenance functions on the identified end item or component. The application of the maintenance functions to the
end item or component shall be consistent with the capacities and capabilities of the designated maintenance level
which are shown on the MAC as:
Field - includes two columns:
"O" which corresponds to Aviation Maintenance Company (AMC)
"F" which corresponds to Aviation Support Battalion (ASB)
The maintenance to be performed below depot and in the field is described as follows:
1. Aviation Maintenance Company (AMC). The primary purpose of the aviation maintenance company is to
support the momentum of offensive operations. Composition of the AMC will be based on type of operations
being supported, nature of the battlefield, and the need for flexibility. AMCs will provide forward positioning
of essential maintenance repair parts and supplies, maximum use of support teams, use of airlift/air drops
for resupply, for maintenance that does not interfere with the tactical plans and operations. AMCs are agile,
mobile, and well equipped. They will carry limited stockpiles of demand supported, essential parts and sup-
plies. The AMC performs battle damage assessment and repair (BDAR) and unit level repairs on Aviation
Life Support Systems (ALSS). The AMC performs production control, quality control, and Maintenance Man-
agement/Maintenance Test Pilot functions. AMCs will rig aircraft for recovery operations. The AMC manages
the battalion maintenance program and operates a central tool room. The AMC conducts forward arming
and refueling. AMCs will be comprised of 3 to 4 modular platoons, which are configured to maintain unit level
operational readiness and aircraft availability:
Headquarters Platoon - Establishes standard operating procedures, receives and processes work
requests, schedules maintenance, maintains status of aircraft, coordinates inspections and test flights
and return of repaired aircraft, enforces quality standards, responsible for safety. Also, obtains, stores,
and issues Classes II, III, IV, and IX, prescribe load list, shop stock and authorized stockage list items.
Airframe Repair Platoon - Tailored to battalion it supports. Performs scheduled and unscheduled
maintenance, troubleshoots faulty components, and removes and replaces aircraft components.
Provides mission capable aircraft to support flight company operations.
Component Repair Platoon - Performs scheduled and unscheduled maintenance, troubleshoots
faulty components, and removes and replaces aircraft components. Performs BDAR and manages
Class IX spare/shop stock. This platoon uses Shop Equipment Contact Maintenance (SECM) trucks
which are multi-capable and self-contained and are used to perform on-site maintenance using en-
hanced power tools, test, measurement, and diagnostic equipment, welding and cutting equipment,
and an air compressor. The SECM truck is highly mobile.
Armament Platoon - Only used in attack battalions and cavalry squadrons. Performs scheduled and
unscheduled maintenance on armament components.
0132 00-1
0132 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
2. Aviation Support Company (ASC) in the Aviation Support Battalion (ASB). Comprised of Headquarters,
Airframe, and Component Repair Platoons. Provides maintenance assistance to aviation units helping them
maintain operational readiness and aircraft availability. Utilizes SECM trucks. Capable of supporting split
based operations in two separate and distinct locations. Performs the following types of maintenance:
a. Intermediate maintenance and logistics support operations.
b. Maintenance actions which require more than 3 days to correct.
c. Phased maintenance and preventive maintenance services.
d. In-depth troubleshooting and diagnosis of airframe and component malfunctions.
e. Repairs airframes and LRU component.
f. Fixes night vision systems, aviation life support systems, aviation electrical and hydraulic components.
g. Limited capability to fabricate hydraulic lines.
h. Repairs engines, prop and rotors, armament, and armament subsystems.
i. Fixes and fuels organic battalion equipment, ground aviation vehicles, and aviation ground support
equipment.
j. Operates and performs field maintenance on aviation ground power units, generator, and ground sup-
port equipment.
k. Battle damage assessment and repair (BDAR).
l. Production control and quality control.
m. Test Pilot functions.
3. Theater Aviation Sustainment Maintenance Group (TASMG). Assists in deployment and redeployment,
provides technical assistance, supports increased operational tempo, sustains Army aviation across the en-
tire spectrum of operations. The TASMG:
a. Provides support to CONUS deploying forces.
b. Provides support to OCUNUS deployed forces.
c. OCONUS aviation maintenance support for contingency and stability and/or support operations.
d. Expands aviation maintenance capabilities of CONUS depots.
e. Classifies and inspects aviation stocks and components.
f. Repairs engines, airframes, armament, composite materials, electrical systems, avionics, hydraulics.
g. Fabricates hydraulics lines.
h. Backup ASB and AMC maintenance functions.
NOTE
Approved item names are used throughout this MAC. Generic terms/nomenclature (if any) are
expressed in parentheses and are not to be considered as official terminology.
This MAC assigns maintenance functions to the lowest level of maintenance, based on past experience and the follow-
ing considerations:
Skills available.
Work time required.
Tools and test equipment required and/or available.
Only the lowest level of maintenance authorized to perform a maintenance function is indicated. If the lowest main-
tenance level cannot perform all tasks of any single maintenance function (e.g., test, repair), then the higher mainte-
nance level(s) that can accomplish additional tasks will also be indicated.
A maintenance function assigned to a maintenance level will automatically be authorized to be performed at any higher
maintenance level.
0132 00-2
TM 1-1680-377-13&P-1 0132 00
INTRODUCTION CONTINUED
A maintenance function that cannot be performed at the assigned level of maintenance for any reason may be evacu-
ated to the next higher maintenance level. Higher maintenance levels will perform the maintenance functions of lower
maintenance levels when required by the commander who has the authority to direct such tasking.
The assignment of a maintenance function will not be construed as authorization to carry the related repair parts or
spares in stock. Information to requisition or otherwise secure the necessary repair parts will be as specified in the
associated RPSTL.
Normally there will be no deviation from the assigned level of maintenance. In cases of operational necessity, at the
request of the lower maintenance level and on a one- time basis, transfer of a maintenance functions to a lower level
may be accomplished by specific authorization of the maintenance officer of the higher level of maintenance to which
the function is assigned. The special tools, equipment, etc., required by the lower level of maintenance to perform this
function will be furnished by the maintenance level to which the function is assigned. This transfer of a maintenance
function to a lower maintenance level does not relieve the higher maintenance level of the responsibility for the func-
tion. The higher level of maintenance will provide technical supervision and inspection of the function being performed
at the lower level.
Maintenance Functions
Maintenance Functions will be limited to and defined as follows:
1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical
characteristics with established standards through examination (e.g., by sight, sound or feel).
2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic or electrical characteristics
of an item and comparing those characteristics with prescribed standards.
3. Service. Operations required periodically to keep an item in proper operating condition,i.e., to clean (in-
cludes decontaminate, when required), to preserve, to drain, to paint or to replenish fuel, lubricants, chemical
fluids or gases.
a. Unpack. To remove from packing box for service when required for the performance of maintenance
operations.
b. Repack. To return item to packing box after service and other maintenance operations.
c. Clean. To rid the item of contamination.
d. Touch up. To spot paint scratched or blistered surfaces.
e. Mark. To restore obliterated identification.
4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or by set-
ting the operating characteristics to specified parameters.
5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measur-
ing or diagnostic equipments used in precision measurement. Consists of comparisons of two instruments,
one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy
of the instrument being compared.
7. Remove/Install. To remove and install the same item when required to perform service or other maintenance
functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part or module
(component or assembly) in a manner to allow the proper functioning of an equipment or system.
8. Paint. To prepare and spray color coats of paint so that the ammunition can be identified and protected. The
color indicating primary use is applied, preferably, to the entire exterior surface as the background color of the
item. Other markings are to be painted as original so as to retain proper ammunition identification.
9. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is au-
thorized by the MAC and assigned maintenance level is shown as the third position code of the Sourse, Main-
tenance, and Recoverability (SMR) code.
10. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installa-
tion, disassembly/assembly procedures, and maintenance actions to identify troubles and restore service-
ability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module
0132 00-3
0132 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
(component or assembly), end item or system. The following definitions are applicable to the "repair" main-
tenance function:
Services. Inspect, test, service, adjust, align, calibrate, and/or replace.
Fault location/troubleshooting. The process of investigating and detecting the cause of equipment
malfunctioning; the act of isolating a fault within a system or Unit Under Test (UUT).
Disassembly/assembly. The step-by-step taking apart (or breakdown) of a spare/functional group
coded item to the level of its least component identified as maintenance significant (i.e., assigned an
SMR code) for the level of maintenance under consideration.
Actions. Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
11. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely service-
able/operational condition as required by maintenance standards in appropriate technical publications.
Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally
return an item to like new condition.
12. Rebuild. Those services/actions necessary for the restoration of unserviceable equipment to a like new con-
dition in accordance with original manufacturing standards. Rebuild is the highest degree of material mainte-
nance applied to Army equipment. The rebuild operation includes the act of returning to zero those age mea-
surements (e.g., hours/miles) considered in classifying Army equipment/components.
0132 00-4
TM 1-1680-377-13&P-1 0132 00
INTRODUCTION CONTINUED
Maintenance Level. The maintenance levels field and sustainment are listed on the MAC with individual columns for
AMC, ASB, TASMG, and Depot that include the work times for maintenance functions at each maintenance level. Work
time presentations such as "0.1" indicate the average time (expressed in manhours in whole hours or decimals) it re-
quires a maintenance level to perform a specified maintenance function. If a work time has not been established, the
columnar presentation will indicate "--". Maintenance levels higher than the level of maintenance indicated are autho-
rized to perform the indicated function.
Tools and Equipment Reference Code. Entry specifies, by code, those common tool sets (not individual tools), com-
mon TMDE, and special tools, special TMDE, and special support equipment required to perform the designated func-
tion.
Tools and Equipment Reference Code. Entry specifies, by code, those common tool sets (not individual tools), com-
mon TMDE, and special tools, special TMDE, and special support equipment required to perform the designated func-
tion.
Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is keyed to the re-
marks.
Explanation of Entries in the Tools and Test Equipment Requirements
Tool or Test Equipment Reference Code. The tool or test equipment reference code correlates with a code used in
tasks and equipment reference code entry of the MAC.
Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.
Nomenclature. Name or identification of the tool or test equipment.
National Stock Number (NSN). The NSN of the tool or test equipment.
Tool Number. The manufacturers part number.
Explanation of Entries in the Remarks
Remarks Code. The code recorded in remarks code entry of the MAC.
Remarks. This entry lists information pertinent to the maintenance function being performed as indicated in the MAC.
SUPPORTING INFORMATION
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
0133 00-1
0133 00 TM 1-1680-377-13&P-1
REPAIR .5 1, 4, 5, 6,
8, 9, 13,
18, 22, 23,
24, 25, 28
REPLACE .1
Extended Equipment INSPECT .1
Pouch (EEP)
REMOVE .1
REPAIR 1.5 1, 5, 6, 8,
9, 13, 14,
22, 23, 24,
25, 28
REPLACE .2
Mask Blower Pouch INSPECT .1
REPLACE .1
Extraction Strap INSPECT .1
REPLACE .1
Safety Restraint Tether INSPECT .1
(SRT)
REPLACE .1
0133 00-2
TM 1-1680-377-13&P-1 0133 00
0133 00-3
0133 00 TM 1-1680-377-13&P-1
0133 00-4
TM 1-1680-377-13&P-1 0133 00
REPAIR 1.5 1, 4, 5, 6,
8, 9, 13,
18, 22, 23,
24, 25, 28
REPLACE .1
M-4 Magazine Pouches INSPECT .1
REMOVE .1
REPAIR 1.5 1, 4, 5, 6,
8, 9, 13,
18, 22, 23,
24, 25, 28
REPLACE .1
Extraction Strap INSPECT .1
REPLACE .1
Safety Restraint Tether INSPECT .1
(SRT)
REPLACE .1
0133 00-5
0133 00 TM 1-1680-377-13&P-1
TOOLS OR
TEST EQUIP MAINTENANCE NATIONAL TOOL
REF CODE LEVEL NOMENCLATURE STOCK NUMBER NUMBER
0133 00-6
TM 1-1680-377-13&P-1 0134 00
SUPPORTING INFORMATION
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
INTRODUCTION TO RPSTL
INTRODUCTION
SCOPE
This RPSTL lists and authorizes spares and repair parts; special tools; special test, measurement, and diagnostic
equipment (TMDE); and other special support equipment required for performance of Operator and Unit Level Main-
tenance of the PSGC. It authorizes the requisitioning, issue, and disposition of spares, repair parts, and special tools
as indicated by the source, maintenance, and recoverability (SMR) codes.
GENERAL
In addition to the Introduction work package, this RPSTL is divided into the following work packages.
1. Repair Parts List Work Packages. Work packages containing lists of spares and repair parts authorized by
this RPSTL for use in the performance of maintenance. These work packages also include parts which must
be removed for replacement of the authorized parts. Parts lists are composed of functional groups in as-
cending alphanumeric sequence, with the parts in each group listed in ascending figure and item number
sequence. Sending units, brackets, filters, and bolts are listed with the component they mount on. Bulk ma-
terials are listed by item name in FIG. BULK at the end of the work packages. Repair parts kits are listed
separately in their own functional group and work package. Repair parts for reparable special tools are also
listed in a separate work package. Items listed are shown on the associated illustrations.
2. Special Tools List Work Packages. Work packages containing lists of special tools, special TMDE, and spe-
cial support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in the
DESCRIPTION AND USABLE ON CODE (UOC) column). Tools that are components of common tool sets
and/or Class VII are not listed.
3. Cross-Reference Indexes Work Packages. There are two cross reference indexes work packages in this RP-
STL: the National Stock Number (NSN) Index work package and the Part Number (P/N) Index work package.
The National Stock Number Index work package refers you to the figure and item number. The Part Number
Index work package refers you to the figure and item number.
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES
ITEM NO. (Column (1)). Indicates the number used to identify items called out in the illustration.
SMR CODE (Column (2)). The SMR code containing supply/requisitioning information, maintenance level authoriza-
tion criteria, and disposition instruction, as shown in the following breakout:
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0134 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
Source Code. The source code tells you how you get an item needed for maintenance, repair, or overhaul of an end
item/equipment. Explanations of source codes follow:
0134 00-2
TM 1-1680-377-13&P-1 0134 00
INTRODUCTION CONTINUED
Source Code Application/Explanation
NOTE
Cannibalization or controlled exchange, when authorized, may be used as a source of supply
for items with the above source codes except for those items source coded "XA" or those AV
support items restricted by requirements of AR 750-1.
Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized to use and repair support
items. The maintenance codes are entered in the third and fourth positions of the SMR code as follows:
Third Position. The maintenance code entered in the third position tells you the lowest maintenance level authorized to
remove, replace, and use an item. The maintenance code entered in the third position will indicate authorization to the
following levels of maintenance:
Fourth Position. The maintenance code entered in the fourth position tells you whether or not the item is to be repaired
and identifies the lowest maintenance level with the capability to do complete repair (perform all authorized repair func-
tions).
NOTE
Some limited repair may be done on the item at a lower level of maintenance, if authorized by
the Maintenance Allocation Chart (MAC) and SMR codes.
0134 00-3
0134 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
Maintenance Code Application/Explanation
F- Direct support/AVIM is the lowest level that can do
complete repair of the item.
H- General support is the lowest level that can do complete
repair of the item.
L- Specialized repair activity (enter specialized repair
activity designator) is the lowest level that can do
complete repair of the item.
D- Depot is the lowest level that can do complete repair of
the item.
Z- Nonreparable. No repair is authorized.
B- No repair is authorized. No parts or special tools are
authorized for maintenance of "B" coded item. However,
the item may be reconditioned by adjusting, lubricating,
etc., at the user level.
Recoverability Code. Recoverability codes are assigned to items to indicate the disposition action on unserviceable
items. The recoverability code is shown in the fifth position of the SMR code as follows:
NSN (Column (3)). The NSN for the item is listed in this column.
0134 00-4
TM 1-1680-377-13&P-1 0134 00
INTRODUCTION CONTINUED
CAGEC (Column (4)). The Commercial and Government Entity Code (CAGEC) is a five-digit code which is used to
identify the manufacturer, distributor, or Government agency/activity that supplies the item.
PART NUMBER (Column (5)). Indicates the primary number used by the manufacturer (individual, company, firm, cor-
poration, or Government activity), which controls the design and characteristics of the item by means of its engineering
drawings, specifications, standards, and inspection requirements to identify an item or range of items.
NOTE
When you use an NSN to requisition an item, the item you receive may have a different P/N from
the number listed.
NOTE
UOC GEN I is for the PSGC 1st Generation.
UOC GEN II is for the PSGC 2nd Generation.
UOC GEN III is for the PSGC 3rd Generation.
DESCRIPTION AND USABLE ON CODE (UOC) (Column (6)). This column includes the following information:
1. The federal item name, and when required, a minimum description to identify the item.
2. P/Ns of bulk materials are referenced in this column in the line entry to be manufactured or fabricated.
3. Hardness Critical Item (HCI). A support item that provides the equipment with special protection from electro-
magnetic pulse (EMP) damage during a nuclear attack.
4. The statement END OF FIGURE appears just below the last item description in column (6) for a given figure
in both the repair parts list and special tools list work packages.
QUANTITY (QTY) (Column (7)). The QTY (quantity per figure) column indicates the quantity of the item used in the
breakout shown on the illustration/figure, which is prepared for a functional group, subfunctional group, or an assem-
bly. A "V" appearing in this column instead of a quantity indicates that the quantity is variable and quantity may change
from application to application.
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGES FORMAT AND COLUMNS
1. National Stock Number (NSN) Index Work Package.
STOCK NUMBER Column. This column lists the NSN in National item identification number (NIIN) se-
quence. The NIIN consists of the last nine digits of the NSN.
NSN
(e.g., 5385-01-574-1476)
NIIN
When using this column to locate an item, ignore the first four digits of the NSN. However, the complete NSN should
be used when ordering items by stock number.
FIG. Column. This column lists the number of the figure where the item is identified/located. The figures are
in numerical order in the repair parts list and special tools list work packages.
ITEM Column. The item number identifies the item associated with the figure listed in the adjacent FIG.
column. This item is also identified by the NSN listed on the same line.
0134 00-5
0134 00 TM 1-1680-377-13&P-1
INTRODUCTION CONTINUED
2. Part Number (P/N) Index Work Package. P/Ns in this index are listed in ascending alphanumeric sequence
(vertical arrangement of letter and number combinations which places the first letter or digit of each group in
order A through Z, followed by the numbers 0 through 9 and each following letter or digit in like order).
PART NUMBER Column. Indicates the P/N assigned to the item.
FIG. Column. This column lists the number of the figure where the item is identified/located in the repair parts
list and special tools list work packages.
ITEM Column. The item number is the number assigned to the item as it appears in the figure referenced in
the adjacent figure number column.
3. Reference Designator Index Work Package. Reference designators in this index are listed in ascending
alphanumeric sequence (vertical arrangement of letter and number combination which places the first letter
or digit of each group in order "A" through "Z," followed by the numbers "0" through "9" and each following
letter or digit in like order).
REFERENCE DESIGNATOR Column. Indicates the reference designator assigned to the item.
FIG. Column. This column lists the number of the figure where the item is identified/located in the repair parts
list or special tools list work package.
ITEM Column. The item number is the number assigned to the item as it appears in the figure referenced in
the adjacent figure number column.
HOW TO LOCATE REPAIR PARTS
1. When NSNs or P/Ns Are Not Known.
First. Using the table of contents, determine the assembly group to which the item belongs. This is necessary
since figures are prepared for assembly groups and subassembly groups, and lists are divided into the same
groups.
Second. Find the figure covering the functional group or the subfunctional group to which the item belongs.
Third. Identify the item on the figure and note the number(s).
Fourth. Look in the repair parts list work packages for the figure and item numbers. The NSNs and part
numbers are on the same line as the associated item numbers.
2. When NSN Is Known.
First. If you have the NSN, look in the STOCK NUMBER column of the NSN index work package. The NSN
is arranged in NIIN sequence. Note the figure and item number next to the NSN.
Second. Turn to the figure and locate the item number. Verify that the item is the one you are looking for.
3. When P/N Is Known.
First. If you have the P/N and not the NSN, look in the PART NUMBER column of the P/N index work package.
Identify the figure and item number.
Second. Look up the item on the figure in the applicable repair parts list work package.
0134 00-6
TM 1-1680-377-13&P-1 0135 00
SUPPORTING INFORMATION
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
0135 00-1
0135 00 TM 1-1680-377-13&P-1
LEFT RIGHT
1
13
2
12
11
10
5
9
7 6
8
MS040344
0135 00-2
TM 1-1680-377-13&P-1 0135 00
GROUP 00
PRIMARY SURVIVAL GEAR CARRIER, GEN I/II
FIGURE 1. PRIMARY SURVIVAL GEAR
CARRIER, GEN I/II
END OF FIGURE
0135 00-3
0135 00 TM 1-1680-377-13&P-1
2 4
13 14 3
12
11 5
10
7
8
9
MS040342
GROUP 01
PRIMARY SURVIVAL GEAR CARRIER (PSGC),
GEN III
FIGURE 2. PRIMARY SURVIVAL GEAR
CARRIER (PSGC), GEN III
0135 00-4
TM 1-1680-377-13&P-1 0135 00
END OF FIGURE
0135 00-5
0135 00 TM 1-1680-377-13&P-1
L
1
6 MS040391
5 4
GROUP 02
BODY ARMOR OVERLAY SYSTEM (BAOS)
FIGURE 3. BODY ARMOR OVERLAY SYSTEM
(BAOS)
END OF FIGURE
0135 00-6
TM 1-1680-377-13&P-1 0135 00
1 2 3
4
15
SPF
INSECT
REPELLENT
BAG, STORAGE
DRINKING WATER
SIZE: B
0.3 FL OZ.
SPEC. MILB8571D
SPO 10095C5114
MFD. 12/1995 5
INSPECTION 12/2000
ASSORTED
FRUIT FLAVORED CANDY
10
FIRE STARTER
AVIATION
STERILE
SURVIVAL
EMERGENCY
SPARKLITE
8 7
MS040314
0135 00-7
0135 00 TM 1-1680-377-13&P-1
GROUP 03
EXTENDED EQUIPMENT POUCH (EEP)
COMPONENTS, GEN I/II
FIGURE 4. EXTENDED EQUIPMENT POUCH
(EEP) COMPONENTS, GEN I/II
END OF FIGURE
0135 00-8
TM 1-1680-377-13&P-1 0135 00
1
2 3
4
ASPRIN
325 mg (5gr) TABLET
ASPRIN
325 mg (5gr) TABLET
1 COMBAT TRAUMA WRAP KIT
1 SHEET 6" X 60"
1 PAGE OF INSTRUCTIONS
GED
DAMA
ASPRIN PART # DMH 1115
325 mg (5gr) TABLET
OR
GED
ENED
DAMA
IF OP
OR
ENED
USE
ILE
NOT
IF OP
STER
ASPRIN
DO
325 mg (5gr) TABLET
USE
ILE
NOT
STER
DAG E
DO
E
BAN ESIV
DAG E
ADH
E
BAN ESIV
ASPRIN
325 mg (5gr) TABLET
ADH
5
BAC
IT
OPH RACIN
OIN
THA
TM
LMI
C
6
ENT
STER USP
ILE
14 7
13
T
CINCH TIGH
SSION
E COMPRE
STERIL ABD PAD
E 8" X 10"
BANDAG
FIRE STARTER
15
SPF
AVIATION
SURVIVAL
TOPICAL ANTISEPTIC
0.3 FL OZ.
BACTERICIDE/VIRUCIDE
12 11 10 8
9
MS040315
0135 00-9
0135 00 TM 1-1680-377-13&P-1
GROUP 04
PSGC/BAOS FIRST AID COMPONENTS
FIGURE 5. PSGC/BAOS FIRST AID
COMPONENTS
END OF FIGURE
0135 00-10
TM 1-1680-377-13&P-1 0135 00
E
W
WARNING
DO NOT EXTEND
SHIELD FOR I.R.
OPERATION
MS040345
GROUP 05
PSGC/BAOS SIGNALING COMPONENTS
FIGURE 6. PSGC/BAOS SIGNALING
COMPONENTS
END OF FIGURE
0135 00-11
0135 00 TM 1-1680-377-13&P-1
2
5
4 MS040366
GROUP 06
PSGC/BAOS ADDITIONAL COMPONENTS
FIGURE 7. PSGC/BAOS ADDITIONAL
COMPONENTS
0135 00-12
TM 1-1680-377-13&P-1 0135 00
END OF FIGURE
0135 00-13
0135 00 TM 1-1680-377-13&P-1
1 3
MS040389
GROUP 07
KNIFE SYSTEM
FIGURE 8. KNIFE SYSTEM
END OF FIGURE
0135 00-14
TM 1-1680-377-13&P-1 0135 00
3 4 3
7
9 8
MS040390
GROUP 08
HOLSTER ASSEMBLY, GEN III
FIGURE 9. HOLSTER ASSEMBLY, GEN III
END OF FIGURE
SUPPORTING INFORMATION
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
NSN INDEX
6505-00-009-5060 5 2 8415-01-514-1072 1 10
6350-00-105-1252 6 4 8415-01-514-1075 1 9
6510-00-201-1755 4 11 2 13
6510-00-203-6010 5 6 1 9
7920-00-240-2559 5 13 8415-01-514-1086 3 7
4020-00-246-0688 4 7 1 13
8465-00-254-8803 6 1 1 13
6515-00-383-0565 7 7 2 12
1370-00-490-7362 6 5 1095-01-518-6832 8 1
6505-00-582-4190 5 14 1095-01-518-6868 8 3
8465-00-634-4499 4 2 1095-01-518-6875 8 2
6510-00-913-7909 5 5 1095-01-518-6877 8 4
6505-00-914-3593 5 12 1095-01-518-6879 8 5
7210-00-935-6666 4 5 1680-01-518-7270 7 3
6850-00-985-7166 4 3 1095-01-519-5174 7 8
8970-01-028-9406 4 10 1095-01-519-5179 7 8
8960-01-124-4543 4 8 6515-01-521-7976 7 7
6605-01-196-6971 6 2 1095-01-530-0826 8 4
1680-01-233-0061 5 9 1095-01-530-0827 8 2
4 6 1095-01-530-0832 8 3
6505-01-238-5632 5 3 1095-01-530-0833 8 1
6230-01-259-4495 7 6 6510-01-538-6292 5 4
7 6 8415-01-546-8380 2 5
8645-01-322-7432 7 4 3 5
8465-01-322-7433 2 2 8465-01-547-9843 2 10
1 2 3 6
6230-01-411-8535 6 3 8415-01-547-9846 3 4
6505-01-436-9606 5 15 2 11
6840-01-452-9582 5 11 1095-01-550-3883 9 5
4 1 1095-01-550-3913 9 1
6515-01-491-5719 5 1 1670-01-550-5338 9 9
6510-01-497-0711 5 8 8415-01-553-0218 2 6
6510-01-503-2109 5 7 3 8
8415-01-513-8143 1 1 8465-01-559-1702 9 8
8415-01-513-8143 2 1 8465-01-559-1707 9 4
8415-01-513-8148 1 3 8465-01-559-1716 9 7
8415-01-514-1061 2 14 6230-01-562-3691 7 6
1 4 1680-01-564-6813 7 1
8415-01-514-1062 1 11 1680-01-572-6710 1 8
8415-01-514-1067 2 3 2 9
1 12 3 9
SUPPORTING INFORMATION
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
2 7
A-A-20331 4 10
1001040 4 4
A-A-20332 4 8
1005804-5 2 1
A-A-50041 2 2
1005804 1 1
7 4
1005809 1 10
A-A-55106 6 1
1005810 1 11
ACR/MS-2000M 6 3
1005811-1 2 3
BANDAGE,MUSLIN 4 11
1005812 1 4
DDD-B-0035 5 5
1005813-1 3 7
DMH1115 5 4
1 13
EF1109D 5 1
2 12
LBT 0370D 9 4
1005815 1 3
LBT 0373-6S 9 8
1005816-1 2 8
LBT 0373B-4F 9 9
1005816-3 2 8
LBT 6099B 9 2
1005816 1 6
LBT 6099E 9 7
1005825-1 2 6
LBT-0372H-LH 7 8
3 8
LBT-0372H-RH 7 8
1005829-1 2 13
LBT-6099H 9 6
1 9
LBT-6099J 9 3
1005840-1 2 14
MIL-B-36964 4 5
1005845-43 9 5
MIL-B-8571D 4 2
1005845-5 9 1
MIL-C-10436 6 2
1005851-1 7 3
MILT36045 7 7
1005942-3 7 1
MILW283 4 3
1005943-1 1 8
NDC00045-0501-30 5 15
2 9
NDC00168-0026-38 5 14
3 9
NDC00182-1035-89 5 2
1005943-1 1 8
NDC51079-0690-20 5 3
1005944-1 3 4
NDC67618-0150-05 5 12
2 11
OPD5 1 2
1005945-1 3 6
P2160-B 7 6
2 10
P5006-4G 4 7
1005946-3 2 5
SL3 5 9
3 5
4 6
1005948-1 2 4
SUNSECT/320 5 11
1005991-1 7 5
PACKETS/BX
1005996-1 7 2
SUNSECT 4 1
1006055-1 7 2
UP401 5 6
1028611-1 3 1
WG0601 6 4
1028612-1 3 2
1001039 1 5
1028613-1 3 3
3 10
103-000-235 7 6
0137 00-1
0137 00 TM 1-1680-377-13&P-1
13/4CL 1 7
1400 8 1 612153-1 1 10
1401 8 3 612300-1 1 11
1402 8 2 612320-1 1 12
1410 8 1 612408-1 1 4
1411 8 3 612412-1 1 13
1412 8 2 612500-1 1 3
1417 8 4 612501-1 1 6
1429 8 5 612603-1 1 9
1WG0415-BX 4 9 6510015032109 5 7
30-0001 7 7 720M 1 7
3583002841 5 8 7920-00-240-2559 5 13
6020-0101 5 10 860-0022-5 7 6
612100-1 1 1 89108839 6 5
0137 00-2
TM 1-1680-377-13&P-1 0138 00
SUPPORTING INFORMATION
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
INTRODUCTION
Scope
This work package lists additional items you are authorized for the support of the PSGC/BAOS.
General
This list identifies items that do not have to accompany the PSGC and that do not have to be turned in with it. These
items are all authorized to you by CTA, MTOE, TDA, or JTA.
Explanation of Columns in the AAL
Column (1) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning pur-
poses.
Column (2) Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N). Identifies the
Federal item name (in all capital letters) followed by a minimum description when needed. The last line below the de-
scription is the CAGEC (in parentheses) and the part number.
Column (3) Usable On Code. When applicable, gives you a code if the item you need is not the same for different mod-
els of equipment.
Column (4) Unit of Issue (U/I). Indicates the physical measurement or count of the item as issued per the National Stock
Number shown in column (1).
Column (5) Qty Recm. Indicates the quantity recommended.
SUPPORTING INFORMATION
PRIMARY SURVIVAL GEAR CARRIER (PSGC)
PART NO. 1005804-5 NSN 8415-01-513-8143 EIC: NA
BODY ARMOR OVERLAY SYSTEM (BAOS)
PART NO. 1028611-1 EIC: NA
EXPENDABLE AND DURABLE ITEMS LIST
INTRODUCTION
Scope
This work package lists expendable and durable items that you will need to operate and maintain the Primary Survival
Gear Carrier (PSGC) and Body Armor Overlay System (BAOS). This list is for information only and is not authority to
requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except
Medical, Class V Repair Parts, and Heraldic Items), or CTA 8-100, Army Medical Department Expendable/Durable
Items.
EXPLANATION OF COLUMNS IN THE EXPENDABLE/DURABLE ITEMS LIST
Column (1) Item Number. This number is assigned to the entry in the list and is referenced in the narrative instructions
to identify the item.
Column (2) Level. This column identifies the lowest level of maintenance that requires the listed item. (C = Opera-
tor/Crew, O = Field/AMC, F = Field/ASB, H = Below Depot Sustainment, D = Depot).
Column (3) National Stock Number (NSN). This is the NSN assigned to the item which you can use to requisition it.
Column (4) Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N). This
column provides the other information you need to identify the item.
Column (5) Unit of Issue (U/I). Indicates the physical measurement or count of the item as issued per the National Stock
Number shown in column (3).
0139 00-1
0139 00 TM 1-1680-377-13&P-1
0139 00-2
TM 1-1680-377-13&P-1 0139 00
42 O D-ring A-A-59557-A4 EA
43 O Wingless snap hook, black (02768) 106-3000-5676 EA
44 O Locking carabiner, FG504 (78848) OPLFG EA
45 O Tension Lock Retainer, black (70474) SL-DB-1 EA
46 O Snap hook, black (70474) WSB EA
47 O Webbing, Nylon Textile, Type IV Class 1/1A, 1 1/2 YD
inch, FG504 PIA-T-5038
48 O Zipper Chain, FG504 1005831-1 YD
49 O Locking Slider, FG504 1005831-3 EA
50 O Zipper, Center Front, 6110 EAD 601-LOFV 11/16 EA
tape, FG504 1005849-1
51 O Laundry Detergent, Non-Chlorine Local Purchase EA
52 O 7920-00-240-2559 Sponge (83421) EA
53 O 8105-01-381-6365 Plastic Wrap 8-inch x 22 Ft. Roll Bulk-8 ( OHUB7) PG
54 O 8105-01-381-6374 Plastic Wrap 11-inch x 22 Ft. Roll Bulk-11 ( OBUB7)) PG
55 O Flame Retardant Textured Nylon Cloth 500 Denier YD
1005936-1
56 O Ring Strap (81996) 1005856-13 EA
RAYMOND T. ODIERNO
General, United States Army
Official: Chief of Staff
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
1206001
DAVID ARCHITZEL
Vice Admiral, United States Navy
Commander, Air Systems Command
Distribution:
TM 1-1680-377-13&P-1 to be distributed in Electronic Media Only.
These are the instructions for sending an electronic 2028
The following format must be used if submitting an electronic 2028. The subject line must be
exactly the same and all fields must be included; however only the following fields are
mandatory: 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 16, 17, and 27.
From: Whomever [email protected]
To: [email protected]
Subject: DA Form 2028
1 From: Joe Smith
2 Unit: home
3 Address: 4300 Park
4 City: Hometown
5 St: MO
6 Zip: 77777
7 Date Sent: 19--OCT--93
8 Pub no: 55--2840--229--23
9 Pub Title: TM
10 Publication Date: 04--JUL--85
11 Change Number: 7
12 Submitter Rank: MSG
13 Submitter FName: Joe
14 Submitter MName: T
15 Submitter LName: Smith
16 Submitter Phone: 123--123--1234
17 Problem: 1
18 Page: 2
19 Paragraph: 3
20 Line: 4
21 NSN: 5
22 Reference: 6
23 Figure: 7
24 Table: 8
25 Item: 9
26 Total: 123
27 Text:
This is the text for the problem below line 27.
Use Part II (reverse) for Repair Parts and DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND
BLANK FORMS
Special Tool Lists (RPSTL) and Supply
Catalogs/ Supply Manuals (SC/SM) 8/30/02
For use of this form, see AR 25--30; the proponent agency is ODISC4.
TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe
ATTN: AMSAM--MMC--MA--NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565
PART 1 - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Organizational, Direct Support, And
TM 9-1005-433-24 16 Sep 2002 General Support Maintenance Manual for
Machine Gun, .50 Caliber M3P and M3P
Machine Gun Electrical Test Set Used On
Avenger Air Defense Weapon System
ITEM PAGE PARA- LINE FIGURE TABLE
NO. NO. GRAPH NO. * NO. NO. RECOMMENDED CHANGES AND REASON
1 WP0005
PG 3
2 Test or Corrective Action column should identify a different WP number.
L E
P
A M
E X
* Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS EXTENSION
PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE
TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED
L E
P
A M
PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
E X
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
MSG, Jane Q. Doe, SFC 788-1234
USAPA V3.01
Use PartII(reverse) for Repair Parts and DATE
Special Tool Lists (RPSTL) and Supply
RECOMMENDED CHANGES TO PUBLICATIONS AND Catalogs/ Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4.
TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command ATTN:
AMSAM-MMC-MA-NP Redstone Arsenal, AL 35898
PART 1 --ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMC-MA-NP Redstone Arsenal, AL
35898
PART II --REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE
TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED
PART III --REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms.
Additional blank sheets may be used if more space is needed.)
USAPA V3.01
The Metric System and Equivalents
1 centigram = 10 milligrams = .15 grain 1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 decigram = 10 centigrams = 1.54 grains 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 gram = 10 decigram = .035 ounce 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 decagram = 10 grams = .35 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 hectogram = 10 decagrams = 3.52 ounces 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 kilogram = 10 hectograms = 2.2 pounds 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons
Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. Inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. Inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Temperature (Exact)