TM 10-8400-203-23&P. Manual - part 16

 TM 

10-8400-203-23&P 

0016 

 

0016-1/2 blank 

  

FIELD MAINTENANCE 

CHEMICAL GEAR 

INSPECT, SERVICE 

 

 

INITIAL SETUP: 

 

 

 

Tools Personnel 

Required 

 

 

N/A 

Non-MOS Specific (1) 

 

 

Materials/Parts References 

N/A  

TM 3-220 

 WP 

0005 

 

WP 0007 

 
INSPECT 
 
Perform PMCS inspection on all items IAW WP 0005 and determine serviceability IAW WP 0007. 

END OF TASK 

SERVICE 

Cleaning.  Refer to TM 3-220 for cleaning and decontamination of protective clothing ensembles. 
 
END OF TASK 
 
END OF WORK PACKAGE 
 
 

 

 

 

 TM 

10-8400-203-23&P 

0017 

0017-1 

FIELD MAINTENANCE 

PERSONNEL ARMOR SYSTEM GROUND TROOPS (PASGT) HELMET 

INSPECT, SERVICE, REPAIR 

 

 

INITIAL SETUP: 

 

 

 

Tools Personnel 

Required 

 

 

Screwdriver, Flat Tip (WP 0046, Item 23) 

Non-MOS Specific (1) 

 

 

Materials/Parts References 

 

 
WP 0005 

Emery Cloth, 120 Grit (WP 0047, Item 10) 

WP 0007 

Polyurethane Coating, MIL-C-46185 Type II, 
Color O.D. 34088 of FED STD 595 (WP 0047, 
Item 39) 

WP 0032 
WP 0046 

Polyurethane Coating, MIL-C-46168, Color D.D. 
34087 of FED STD 595 (WP 0047, Item 40) 

WP 0047 

Walnut Shell Flour, 40/1 00 Mesh (WP 0047, 
Item 41) 

 

Adhesive, EC 1357 (WP 0047, Item 42) 

 

Adhesive, Paste, 2 oz. (WP 0047, Item 43) 

 

Adhesive (for Edging) (WP 0047, Item 36) 

 

 
INSPECT 
 
Perform PMCS inspection on all items IAW WP 0005 and determine serviceability IAW WP 0007. 

END OF TASK 
 

 TM 

10-8400-203-23&P 

0017 

0017-2 

SERVICE 

Field Cleaning 
 

CAUTION 

 

Do not use Chlorine Bleach, yellow soap, cleaning fluids or solvents. Such products will 
discolor and deteriorate component materials. 

 

Do not launder or dry items in fixed, commercial/home laundry equipment. Material will be 
degraded. 

 
 

1.  Scrape dirt or mud from the equipment using a flat stick or a dull instrument which will not cut the 

fabric or webbing. 

2.  Wash the helmets 10-15 minutes in a 0.5 percent soap solution at a water temperature of 120° F (40° 

C).  

3.  Rinse them in clear warm water until soap is removed.  

4.  Allow them to dry thoroughly in a temperature not exceeding 140°F (60°C). 

 
END OF TASK 
 
Cleaning for Issue 
 
1.  The equipment will be cleaning in soak and wash tanks in the same manner as other light weight load 

carrying equipment. Laundry washing machines will not be used.  

2.  Remove loose dirt or dust from the items to be washed using a brush, cloth, or vacuum attachment. 

3.  Remove staves from field pack. 

4.  Soak items for at least five minutes or longer as necessary in a tank containing warm water. 

5.  Wash the items in a solution of Type II powdered laundry detergent scrubbing vigorously with a soft 

brush cloth or sponge as necessary. 

6.  Flush the washed equipment with clean, warm water until all cleaning solution has been rinsed out. 

7.  Air dry the equipment away from direct sunlight and heat, or open flames. 

END OF TASK 

Paint 

1.  Sand chipped area slightly before touch up painting, making sure not to cause any raised fibers.  

2.  Clean area with a cloth.  

3.  Brush on one coat of the paint. 

4.  Sprinkle a small amount of silica sand or walnut shell flour on the freshly painted area until the 

quantity of sand or walnut shell is equal to that in the original finish.  

5.  Lightly apply a second coat of paint to cover the unpainted particles and allow the area to dry at least 

eight hours.  

6.  Install a new suspension system and chin strap IAW section titled Suspension Line and Chin Strap 

Replacement.  

7.  Examine the inside and outside surfaces of the helmet shell for raised or abraded fibers, cuts, pitting 

or slight indentations. If it is determined that the above defects are limited to the outside plies only (on 
the inside and outside of the shell), and the defects do not extend beyond one ply deep, then the 
helmet shell can be repaired. If damaged extends beyond one ply deep, then the helmet shell is not 
serviceable. Repair of the above defects is accomplished by the following procedures: 

 TM 

10-8400-203-23&P 

0017 

SERVICE – CONTINUED  

0017-3 

8.  Remove paint around the immediate area of damage, making sure not to cause additional raising of 

fibers. 

9.  Wipe clear with cloth to remove dirt and dust particles. 

10.  Apply one coat of epoxy adhesive to sufficiently cover damaged area. Let cure. 

11.  After epoxy has cured, sand lightly and blend smoothly into shell. 

12.  Apply second coat if required. 

13.  Apply paint as described above.  

GENERAL REPAIR 

Suspension Line and Chin Strap Removal 

1.  Remove the six mounting screws and A-nuts; remove the suspension.  

2.  Replace new suspension and hardware if necessary by lining up the holes in the helmet, making sure 

the drawstring pull tab is at the rear of the helmet.  

3.  Insert the A-nut (peak of A toward the rim) through the holes and replace the six screws.  

4.  Remove the screws and remove the chin strap.  

5.  Replace new chin strap as shown making sure the snap fastener is on the left side of the helmet as 

worn. 

END OF TASK 

Rubber Edging Repair  

1.  Examine the rubber edging for cuts, slits, and areas of non-adherence.  

2.  If it is determined that the edging is no longer serviceable, then remove the edging by using a heat 

gun to loosen the adhesive where the edging ends butt together at rear of helmet.  

3.  Once one end of the edging has been loosened, grasp edging with pliers and pull edging away from 

helmet while still using heat gun to loosen adhesive.  

4.  Remove any remaining adhesive before installing new edging to helmet.  

5.  The rubber edging, slightly longer than the periphery of the helmet, should be opened up and wound 

around a cylinder so that the inside of the channel is exposed. The inside of the edging should be 
lightly abraded with a wire brush and the adhesive.  

6.  Adhesive should also be applied to the helmet edge.  

7.  When the adhesive becomes tacky, the edging should be applied to the helmet edge.  

8.  The application of the edging should start at the bench mark at the rear of the helmet and follow the 

periphery of the helmet completely around to the starting point at the rear of the helmet.  

9.  The edging should be cut so that the ends butt each other. 

END OF TASK 

Paint Helmet 
 
Examine the helmet shell for chipped paint. Repair these places without stripping the paint from the 
helmet. Paint the helmet, except that the second coat should cover the entire outside of the helmet 
(including rubber edging)  
 
1.  Remove paint around the immediate area of damage, making sure not to cause additional raising of 

fibers.  

2.  Make a single cut in the blister (fabric ply) with a sharp knife sufficiently long enough to allow placing 

of epoxy resin under the cut ply. 

 TM 

10-8400-203-23&P 

0017 

GENERAL REPAIR – CONTINUED  

0017-4 

3.  Insert epoxy resin under ply in sufficient quantity to achieve a strong bond. 

4.  Apply pressure to defect area to ensure mating of plies. 

5.  After epoxy has cured, sand lightly and blend smoothly into shell. 

6.  Apply second coat of resin if required. 

7. Apply 

paint. 

END OF TASK 

Suspension and Chin Strap Replacement 

1.  Examine the inside and outside surfaces of the helmet shell for delaminations. If it is determined that 

the defect is limited to the outside plies only (on the inside and outside of the shell), and the defect 
does not extend beyond one ply deep, then the helmet shell can be repaired. If damage extends 
beyond one ply deep then the helmet shell is not serviceable. 

2.  Remove paint around the immediate area of the damage, making sure not to cause additional raising 

of fibers. 

3.  Wipe dean with cloth to remove dirt and dust particles. 

4.  Apply one coat of epoxy adhesive under raised ply.  

5.  Apply pressure to defect area to ensure mating of plies. 

6.   After cure is achieved, sand lightly and blend smoothly into shell. 

7.  Apply second coat if required. 

8. Apply 

paint. 

 
END OF TASK 

END OF WORK PACKAGE 

 

 TM 

10-8400-203-23&P 

0018 

0018-1 

   

FIELD MAINTENANCE 

BALACLAVA 

INSPECT, SERVICE, REPAIR 

 

 

INITIAL SETUP: 

 

 

 

Tools Personnel 

Required 

 

 

Knife, Hot Metal (WP 0046, Item 9) 

Non-MOS Specific (1) 

Ruler, Tab, Metal, 16-inch (WP 0046, Item 39) 

 

Sewing Machine, Bar Tack (WP 0046, Item 25) 

References 

Sewing Machine, Medium Duty (WP 0046, Item 
34) 

 
WP 0005 

Tape, Measuring (WP 0046, Item 39) 

WP 0007 

Shears (WP 0046, Item 36) 

WP 0030 

 

 

Materials/Parts  

 

 

Elastic Cord, OD-7, Class 2 (WP 0033, Item 21) 

 

Webbing, OD 106, Type II (WP 0033, Item 22) 

 

 

 

 
INSPECT 
 
Perform PMCS inspection on all items IAW WP 0005 and determine serviceability IAW WP 0007. 

END OF TASK 
 
SERVICE 
 
Cleaning 
 
1.  Launder in accordance with FM 10-280. 

2.  Do not tumble dry, or wring/twist.  

3.  Air dry at room temperature. 

4.  Hand wash in warm water using mild detergent. 

5.  Rinse in clear warm water and hang to drip dry at room temperature. 

6.  Do not dry clean. 

END OF TASK 
 

 

 TM 

10-8400-203-23&P 

0018 

0018-2 

REPAIR 
 
Sewing machine repairs, stitching and re-stitching. All sewing, except emergency repair, shall be 
machine sewn. When ends of machine stitching type 301 are not caught in other seams or stitching, they 
shall be back-stitched not less than 1 inch (2.54 cm) at each break. Ends of a continuous line of stitching 
shall overlap not less than 

1/2 

inch (1.27 cm). Thread breaks (all stitch types) shall be repaired by stitching 

back of the break not less than 1/2 inch (1.27 cm) at end of break. Thread tension shall be properly 
maintained to avoid loose stitching and locks shall be imbedded in the center of the materials sewn. 
Thread breaks in overedge stitching shall be overlock stitched not less than 

3/4 

inch (1.91 cm) at each end 

of break. Stitch spacing used for restitching and other type of seams shall be the same as in the original 
construction. Seams with loose and/or weak thread shall be restitched, 
 
Darning 
 
Small holes or tears. Small holes or tears may be repaired by drawing the edges together and darning 
by hand. 
 
END OFTASK 
 
PULL CORD REPLACEMENT 
 
1.  Replace missing or torn pull tabs with new tabs fabricated of same materials as removed. 

2.  Replace missing or defective elastic cords with elastic cord as specified in Table 1.   

3.  Cut 18 inches 

4.  (44.7 cm) in length, and attach in same manner as the original: Center abutted ends of elastic cordon 

seam allowance at center top cover (cloth, knit aramid) and attach to cover seam allowance with a ½ 
inch (1 .27 cm) bar tack placed through each end of the elastic cord, The long dimension of each bar 
tack shall be in the length direction of the cord. Repair the stitching for the tunnel elastic, taking care 
not to catch elastic in stitching.  

5.  Cut away faded or missing instruction labels and replace with new labels in same location, using type 

301 stitch and label cloth specified. 

Table 1. Stitch Formations. 

 

LOCATION 

STITCH 
TYPE NEEDLE 

BOBBIN 

STITCHES 
PER INCH 

Bar tack-Pull tab  

Bar tack 

B 

B 

38-42 per tack 

Join front and back bib at side seams  

515, 516 or 

519 

B B  6-10 

Overedging  

503 or 504 

B 

B 

6-10 

General  

401 

B 

B 

8-12 

Attach label to face side of lining, attach side vent 
insert to side interlining, and join edge of each 
interlining to insert bar tack  

301 or 401 

B 

B 

8-12 

Bar tack-Center interlining to center abutted ends of 
elastic cord on seam allowance and attach to cover 
seam allowance  

 

B 

B 

24-28 per tack 

 
END OF TASK