TM 10-8400-203-23&P. Manual - part 17

 

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TM 10-8400-203-23&P. Manual - part 17

 

 

 TM 

10-8400-203-23&P 

0018 

0018-3/4 blank 

SIZING 
 

Table 2. Sizing Chart. 

 

AREA TO BE MEASURED 

MEASUREMENT 

TOLERANCE 

Length*  

24 

+ 1 inch 

Width**  

+ 3/4 inch 

Face opening***  

9 1/2 

+ 1/2 inch 

 

1.  Place hood face side upon a flat surface, align bottom edges of front and back of bib and butt top and 

bottom edges of facial opening. With hood in this position measure in a straight line from folded edge 
of crown at highest point to bottom of hood at lowest point on bib. 

2.  With hood positioned in footnote * measure across the hood in a straight line from folded edge to 

folded edge. The line of measurement shall be perpendicular to the length measurement and 1 /2 to 1 
inch (1 .27 to 2.54 cm) below the tuck. 

3.  Fold hood in half lengthwise so fold runs in the length direction of the center top cover and center 

neck cover.  

4.  Place folded hood on flat surface with edges of face opening even.  

5.  Place one hand on neck end of face opening, holding hood against surface with other hand, slide top 

of hood along surface toward back of hood until curvature along the side edges of face opening 
approximates a straight line.  

6.  With hood in this position measure along the edge of face opening from fold at center neck cover to 

fold at center of top cover. 

END OF TASK 
 
END OF WORK PACKAGE 

 

 

 

 TM 

10-8400-203-23&P 

0019 

0019-1 

FIELD MAINTENANCE 

ADVANCED COMBAT VEHICLE CREW HELMET 

INSPECT, SERVICE, REPAIR 

 

 

Tools Personnel 

Required 

Die Tool, Fastener (WP 0046, Item 1) 

 

Die, Eyelet (WP 0046, Item 2) 

Non-MOS Specific (1) 

File, Hand, Flat (WP 0046, Item 3) 

 

Holder, Die (WP 0046, Item 7) 

References 

Holder, Die Fastener (WP 0046, Item 8) 

 
WP 0005 

Pliers, Diagonal Cutting (WP 0046, Item 10) 

WP 0007 

Pliers, Lineman’s (WP 0046, Item 11) 

WP 0033 

Pliers, Needle Nose (WP 0046, Item 12

WP 0046 

Pliers, Slip Joint (WP 0046, Item 13) 

WP 0047 

Screwdriver, Flat Tip (WP 0046, Item 23

 

Screwdriver, Flat-Tip, 1/4-Inch (WP 0046, Item 
24) 

Materials/Parts 

Ruler, Tab, Metal, 16 Inches (WP 0046, Item 19) 

Refer to WP 0033 for complete parts listing. 

 

 

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

END OF TASK 
 
SERVICE 
 
General Cleaning Procedures 
 

CAUTION 

 

Remove batteries from the battery box before cleaning. 
 
Do not use a pointed tool when removing foreign matter from swivel joints and moveable parts. 
Be careful not to puncture ear-cushioning seals.  
 

NOTE 

 

For saltwater operations, complete headset, including internal electronics, must be rinsed with fresh 
water and air-dried daily. 

 
1.  Clean the helmet shell with soap and warm water.  

2.  Rinse with clean water.  

3.  Clean the synthetic rubber edging of the shell with a clean cloth to remove dirt, dust, oil, grease, and 

perspiration. Ensure all communication components such as cords, microphone, microphone boom, 
connectors, and ear pads are free of any dirt or contamination.  

 TM 

10-8400-203-23&P 

0019 

SERVICE – CONTINUED  

0019-2 

4.  Remove loose dirt with a clean, soft cloth damped with a mild detergent solution.  

5.  Remove grease, fungus, or grime with a soft brush and mild detergent.  

6.  Hand wash camouflage cover in warm water (about 120° F) and mild laundry detergent or machine 

wash on permanent press cycle.  

7.  Rinse thoroughly with clean warm water after laundering.  

8.  Hang and let air-dry.  

9.  Clean the Helmet Liner Assembly Components as necessary by removing and washing the 

components with a mild solution of detergent and water.  

10.  Air dry components after washing. 

 
END OF TASK 
 
REPAIR 
 
Only qualified personnel shall accomplish work. The finished ACVC components shall be complete, 
clean, and free from defects affecting their serviceability and appearance. Threads shall be neatly 
trimmed. Sealed seams shall show no leakage when tested. Seams shall not be twisted, pleaded, or 
puckered. Stitch tension shall be adequate, not loose or tight, with specified number of stitches per inch 
on major portions of seam. The material shall not be defective or damaged in any manner. The material 
shall not contain cuts, tears, mends, burns, needle chews or holes. 
 
Helmet Shell Repair 
 
Repairs the helmet shell only in accordance with WP 0018.  
 
END OF TASK 
 
Rubber Edging Repair 
 
Repair synthetic rubber edging by re-bonding it to the helmet shell edge or bonding the appropriate 
lengths of new edging to replace a damaged portion. Roughen the surfaces before bonding adhesive 
edging. 
 
END OF TASK 
 
Repairing the headset component 
 

When repairing any headset component (as seen below for the left and right earcups), care should be taken to 
identify cables during disassembly to facilitate proper reassembly. All cables are colored coordinated (I.E. Red 
to Red, Blue/White to Blue/White, Green to Green, etc). All cable and switch entries should be resealed after 
assembly with any standard commercially available silicone sealant to preserve waterproofing and the sound 
attenuation, which protects hearing and aid in intelligible communications (Figure 1).  
 

 TM 

10-8400-203-23&P 

0019 

SERVICE – CONTINUED  

0019-3 

 

 

Figure 1. ACVC Microphone Assembly. 

 
To repair the Mic/Boom Assembly, remove the foam inserts from the right earcup. Take note of the order of 
assembly. Unplug the connectors with the red & white wires inside the earcup and unscrew the Assembly from 
the outside using a wrench or pliers. Remove any sealant from the threads of the earcup and carefully hands 
tighten the Assembly into the earcup. Using the same removal tool, grasp the hex nut closest to the threads 
and tighten the Assembly into the earcup taking care not to strip the plastic threads. Seal around the Assembly 
from inside the cup with silicone sealant to preserve waterproof characteristics and the noise cancellation 
characteristics, plug in the connector with the red & white wires. 

 
When repairing any headset component (Figure 2), care should be taken to identify cables during 
disassembly to facilitate proper reassembly. All cables are colored-coordinated. All cable and switch 
entries should be resealed after assembly with any standard commercially available silicone sealant to 
preserve waterproofing and the sound attenuation, which protects hearing and aid in intelligible 
communications. When replacing earphones simply remove the foam inserts from the earcup, taking note 
of the order of assembly. Unplug the color-coded wires/connectors from within and reconnect the same 
way. Replace the earphone assembly and foam inserts in the same order as removed. 

 TM 

10-8400-203-23&P 

0019 

SERVICE – CONTINUED  

0019-4 

 

 

Figure 2. Headset Assembly. 

 
END OF TASK 
 
Repairing the Mic/Boom 

Assembly

 

 
1.  Take note of the order of assembly, and remove the foam inserts from the right earcup.  

2.  Unplug the connectors with the red & white wires inside the earcup and unscrew the 

Assembly

 from 

the outside using a wrench or pliers.  

3.  Remove any sealant from the threads of the earcup and carefully hands tighten the 

Assembly

 into the 

earcup.  

4.  Using the same removal tool, grasp the hex nut closest to the threads and tighten the 

Assembly

 into 

the earcup taking care not to strip the plastic threads.  

5.  Seal around the 

Assembly

 from inside the cup with silicone sealant to preserve waterproof 

characteristics and the noise cancellation characteristics, plug in the connector with the red & white 
wires. 

END OF TASK 
 
Repairing the Talk-Through Switch 
 
1.  Taking note of the assembly order, remove the foam fillers and earphone assembly from the right ear-

cup.  

2.  Unplug the mini connectors coming from the switch to the cables and printed circuit board.  

3.  Unscrew the hex nut from the outside of the ear-cup and slide the switch out thru the inside of the 

ear-cup.  

4.  Replace in reverse order and seal around switch with silicone on the inside of the ear-cup. 

 
END OF TASK 

 TM 

10-8400-203-23&P 

0019 

SERVICE – CONTINUED  

0019-5 

Repairing the Talk Circuit 
 
1.  Take note of the order of assembly and remove the foam inserts and earphone from the right earcup 

(Figure 3).  

2.  Unplug the Printed Circuit Board from the three mini-connectors.  

3.  Replace the Printed Circuit Board and test the talk circuit. If fault persists, remove the screen and 

washer from the outside front of the earcup with a small screwdriver.  

4.  Push the Microphone into the earcup. Remove the silicone sealant from the inside of the earcup and 

replace the microphone from the inside. 

5.  Seal the microphone in place with silicone sealant. Use a small amount of sealant around the edge of 

the new screen assembly packaged with the microphone and press into place on the outside of the 
earcup.  

6. Reassemble 

earcup. 

 

 

Figure 3. Talk Circuits. 

END OF TASK 
 
Repairing the Function Switch 
 
1.  When removing function switch, take note of the order of assembly and remove the foam inserts and 

earphone from the left earcup.  

2.  Unplug the mini connectors on the wires coming from the switch and the cables. Remove the hex nut 

from the switch on the outside of the earcup and slide the switch out through the inside of the earcup. 
Re-assemble in reverse order and seal the switch inside the earcup with silicone sealant. 

 
END OF TASK 
 
Repairing the Earcup Tension/Adjustment Strap  
 
1.  Ensure the camouflage cover is removed from shell. Open ratchet buckles on retention system, and 

pull adjustment straps out of ratchet buckles.  

2.  Fully extract adjustment strap. Perform this procedure for both sides.  

3.  Unsnap the back piece of the tension strap assembly. Replace damaged components as necessary. 

Attach right headset tension strap to faceguard attachment strut by sliding tension strap through slot 
opening.  

 TM 

10-8400-203-23&P 

0019 

SERVICE – CONTINUED  

0019-6 

4.  Slide tension strap through tunnel on ear-cup. With ratchet adjustment lock open, slide strap end 

through adjustment lock slightly. Close adjustment lock. Repeat procedure for other side.  

5.  To release, and before removing helmet, pull up on adjustment lock buckles and slide straps 

sufficiently back to clear ears. 

END OF TASK 
 
REPAIR 
 
Routine maintenance involves replacing damaged earcup seals and batteries for the talk-through system, 
as needed. This headset and microphone kit is designed to come apart easily, and since everything plugs 
together with connectors, tools are not needed to replace most parts. There is only one way that things fit 
together. You can’t make a mistake unless you force something into place. 
 
Replacing the Camouflage Cover 
 
1.  Remove the camouflage cover by sliding headset tension adjustment straps through the rear holes of 

cover, and simply remove cover from helmet shell.  

2.  To replace camouflage cover, slide adjustment tension straps through the cover’s rear holes and pull 

the rest of the cover over the entire helmet. Ensure the nylon elastic keeper is securing the cover to 
the shell. 

END OF TASK 
 
Replacing the Retention System 
 
1.  Remove impact liner assembly.  

2.  Starting with the right side, unscrew the retention straps from the upper inside faceguard strut while 

holding the outside screw in place.  

3.  Unscrew the retention straps from the inner backside of the helmet shell.  

4.  Release the ratchet buckles on the back of the helmet, and pull the adjustment straps through. 

5.  Push/pull the adjustment straps free, through and out of the headset tunnels and struts.  

6.  Remove the earcup to earcup cable from the nape strap.  

7.  Remove earcups from damaged retention system by pulling apart retention system cloth free from 

earcup notch.  

8.  Remove damaged retention system. 

9.  To install new retention system, place right earcup on top of hole opening on right side.  

10.  Insert edge of retention system cutout into the earcup notch.  

11.  While pushing up on earcup from bottom, slide remaining retention system edge into earcup notch 

until earcup is completely engaged.  

12.  Attach the retention system to helmet shell, by screwing the retention straps onto the inside of the 

struts, and to the inside rear of helmet shell. Repeat procedure for second earcup.  

13.  Slide earcup adjustment strap through the strut, through the headset tunnel and finally through the 

ratchet buckle in the rear.  

14.  Secure earcup tension adjustment strap by fastening the ratchet buckle. Repeat for opposite side.  

15. Secure earcup-to-earcup cable within the nape strap by fastening the cable into the hook and pile 

fastener. 

END OF TASK 
 
 

 

 

 

 

 

 

 

 

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