Fire-fighting Helmets / Preventive care, control
and maintenance
Fire-fighting helmets
F1 range : F1 / F1S / F1E / F1SF
F2 range : F2 / F2XTREM
Technical Training Document
Maintenance Guidelines
• Preventive care, control and maintenance
• Conformity criteria and replacement of parts
• Disassembling and mounting procedure
• Adjustments
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Fire-fighting Helmets / Preventive care, control
and maintenance
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SUMMARY
Summary..................................................................................................................................2
Introduction...............................................................................................................................4
Presentation of MSA Gallet..................................................................................................4
Preventive care of F1 helmet ...................................................................................................5
Purpose of controls on the helmets.......................................................................................... 6
Applicable standards / Legal requirements.......................................................................... 6
Responsibility of Manufacturer.........................................................................................6
Responsibility of Employer...............................................................................................6
Responsibility of User.......................................................................................................6
Controls................................................................................................................................6
Control Frequency............................................................................................................6
Traceability and maintenance follow-up...........................................................................7
F1 Helmets components ..........................................................................................................8
F1 helmet .............................................................................................................................8
F1S Helmet ..........................................................................................................................9
F1E Helmet ........................................................................................................................10
F1 SF15 Helmet – Version EN 443:1997...........................................................................11
F1E – version EN443:2008................................................................................................12
F1 SF25 – Version EN443:2008 ........................................................................................13
Conformity criteria of F1 components ....................................................................................14
List of conformity criteria ....................................................................................................14
1) Control of the shell (all models)..................................................................................14
2) Control of visors, axes and knobs (all models)........................................................... 16
3) Control of inner shell and inner elements...................................................................18
4) Important Remark.......................................................................................................19
Adjustment of the helmet........................................................................................................20
Standard Cradle.................................................................................................................20
Ratchet Harness.................................................................................................................20
Replacement of spare parts guidelines..................................................................................21
Required Equipment...........................................................................................................21
F1/F1S helmet....................................................................................................................21
F1E Helmet – Specific operations......................................................................................24
Assembly procedure for F1SF helmet....................................................................................26
Assembly of visors .............................................................................................................26
Assembly of inner shell, chinstrap and interfaces.............................................................. 26
It is recommended to assemble both sides one after the other......................................26
Kit Fix assembly .............................................................................................................26
Assembly of accessory interfaces (lamp interface)........................................................27
Inner shell assembly.......................................................................................................28
Assembly of the chinstrap in the helmet shell ................................................................29
Inner paddings assembly ...................................................................................................30
Rigid padding installation (PU).......................................................................................30
Comfort padding assembly (PE).....................................................................................30
Cradle assembly.................................................................................................................31
Ratchet Cradle................................................................................................................ 31
Conformity criteria for F2 components...................................................................................33
Control procedure...............................................................................................................33
List of conformity criteria ....................................................................................................33
1) Helmet Shell...............................................................................................................33
Fire-fighting Helmets / Preventive care, control
and maintenance
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2) Rigid inner padding (PSE)..........................................................................................33
3) Soft inner padding (PE) :............................................................................................34
4) Cradle.........................................................................................................................34
5) Chinstrap....................................................................................................................34
6) Orange Fire goggle ....................................................................................................34
Disassembling the F2 helmet.............................................................................................34
Conformity criteria for F2 X-TREM components ....................................................................35
Control procedure...............................................................................................................35
Control the ratchet and chinstrap ...................................................................................35
Shell ...............................................................................................................................36
Re-assembling the helmet..................................................................................................36
Fire-fighting Helmets / Preventive care, control
and maintenance
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INTRODUCTION
Presentation of MSA Gallet
The company GALLET was created in 1919 with, back then, a main business in leather
industry.
In 1951, GALLET manufactured its first aluminium helmet, and since then, GALLET has
increased its activity to become European leader in head protection devices.
The brand awareness of GALLET move one step forward with the introduction
in 1985 of the F1 fire-fighting helmet for the Paris Fire-fighting Brigade (BSPP).
In 2002, CGF GALLET join the MSA group, MSA being a worldwide leader in the field of
individual and group protection equipment and solutions. (over 4000 people in more than 25
countries). CGF GALLET became
MSA GALLET.
Today, MSA Gallet (35 millions Euros turnover, 250 employees) includes 4 main activities in
the field of head protection :
Civil Security and Protection :
• F1 range for structural fire-fighting
• F2 / F2 X-TREM range for outdoor operations (forest fires, rescue and cleaning,
etc.)
• Breathing apparatus (SCBA)
• Accessories and options (goggles, lamp, etc.)
Military, with combat helmets and peacekeeping helmets, among which the « Blue Helmet »
for UN peacekeeping soldiers.
Police and administration with low enforcement helmets (with or without
ballistic protection)
Aircraft industry with helmets for helicopter pilots and jet fighter aircraft pilots
Moreover, MSA GALLET now offers a broad range of products for individual protection
(respiratory protection, ear protection ocular protection, etc.) and group protection (gas
detection, instrumentation, etc.) for the following industries :
- Civil security
- Iol and Gas industry
- General Industrial protection
- Police and military forces protection
Fire-fighting Helmets / Preventive care, control
and maintenance
PREVENTIVE CARE OF F1 HELMET
Your helmet is a personal protective equipment (PPE) which lifetime strongly depends on the
way it is taken care of (preventive care, storage, etc.)
Following these advices will greatly contribute to maintain the F1 helmets in good condition
and will extend its lifetime.
After each use, and prior to store the helmet, clean the shell and visors with
solvent-free products. Only the products supplied by MSA (Poli F1 for nickel
shell /f1 and EN443:1997), Clear Pilot for the visors) can provide optimal
cleaning performance. For painted shell, including the use only water +
cleaning soap.
Poli F1 Clear Pilot Gel
Using cleaning products containing solvents can result in an important decrease of
mechanical and thermal performances of the helmet, with the risk of loosing
compliance with the safety requirements.
Avoid exposing the helmet to exhaust fumes : always store the helmet in a
protection bag after use (available as accessories), as much as possible in a
dry and clean area (locked closet for instance).
Set properly the helmet on your head to optimize comfort and reduce wearing
out of the internal elements by abrasion
Use retro-reflective stickers on the helmet to improve visibility even in tough,
high fume operating conditions.
Never modify your helmet : it is a category 3 PPE and any modification, even if
it seems very minor (engraving the shell, adding a label, etc.) results in the
automatic lost of compliance with the applicable safety standards.
Use only spare parts supplied by MSA Gallet : they are the only approved ones,
and the use of non conform spare parts will result also in lost of compliance.
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Fire-fighting Helmets / Preventive care, control
and maintenance
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PURPOSE OF CONTROLS ON THE HELMETS
Applicable standards / Legal requirements
F1 helmets are, according to European Directive 89/686/CEE (July 1995)
Category 3 Personal Protective Equipment
As a result, there are several rules that apply and that must be fulfilled to maintain these
helmets on the market (sell and use).
Responsibility of Manufacturer
The manufacturer / supplier of Category 3 PPE must :
1. Supply a user’s guide for the PPE
2. Provide all information related to PPE care
3. Provide all information related to PPE maintenance
Responsibility of Employer
The employer must :
Select the PPE adapted to the conditions of use and risks
Provide PPE to the user free of charge
Control they are properly used when required
Provide tools and resources to maintain them properly
Replace defective PPE
Responsibility of User
The user (wearer) must:
1. Use the defined PPE
2. Take good care of the PPE and maintain it clean
Controls
In order to maintain the PPE is good operating conditions, and conform to the level of
protection they are supposed to offer, it is necessary to periodically carry out conformity
controls of the different elements.
Control Frequency
The control frequency shall be defined as follows :
- Minimum frequency : one control every 2 years
- Depending on the frequency of use and actualo application conditions, a shorter
frequency for controls is desireable (e.g. every year).
- Always control the helmet after use in tough conditions with strong exposures,
such as those listed below.
- Always control the helmet in case of doubt on one component or more
Fire-fighting Helmets / Preventive care, control
and maintenance
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- Traceability is required : recording of controls and of all modifications (parts
exchanged) on the helmet during its life span.
- A periodical control requires a complete disassembly of the helmet
Examples for „exceptional conditions/ strong exposure“ (indicative, not limited
to):
Horizontal, frontal or vertical shock (impact, falling objects, compression, etc.)
Direct exposition to flames
Direct exposition to a heat source
Prolongated use in a zone with very elevated temperature
Exposition to chemical products and/or molten metal
Exposition to electric current
Continued immersion in liquids
Traceability and maintenance follow-up
Chaque casque devrait être identifié individuellement :
• With a unique identifier (manufacturer’s serial number, personal identifier, etc.)
• Use labels applied inside the helmet shell (nothing graved in outside)
• Keep good records of all operations performed (Excel database for instance)
• When replacing a complete helmet, some good parts can be taken from the replaced
configuration (internal parts, chinstrap, etc.)
Control of a helmet on average takes 20 minutes.
Each element must be controlled and its conformity assessed with a reference. The
reference for the different parts are presented in the next chapter.
These are the conformity criteria of F1 helmets and components.
Fire-fighting Helmets / Preventive care, control
and maintenance
F1 HELMETS COMPONENTS
F1 helmet
F1 helmets were delivered between 1985 and 1999
They are all fitted with a standard cradle and a soft, foam padding
F1 helmet components
A Shell - GA0N2200 (nickel)
GA0N2000 (painted helmet)
L Foam padding – discontinued
B Face shield – GA1007 M Inner shell – GA1003H
C Ocular visor – GA1006 N Inner shell inserts – GA1004
D Net – GA1012K O Knobs and spindles – GA1008E
E Chinstrap – GA1009C P Pin – GA1022 (sold by 20)
F Chincup – GA1016A Q Cheek pads – GA1023B
G Shell inserts - GA1041 R Front plate – GA1100*-H Chinstrap ends – not available as SP S Mask plate – GA1015
I Neck plate – GA1013A T Coat of arms (Option)
J Neck pads – GA1014B U Headband support – included in D
K Headband – GA1011C
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Fire-fighting Helmets / Preventive care, control
and maintenance
F1S Helmet
F1S helmets (head size 50-59 cm) were delivered between 2000 and 2008.
They can be fitted with a standard harness or a ratchet harness (since 2002)
F1S helmet components
1
Shell - GA0N2200 (nickel)
GA0N2000 (painted helmet)
11
Neck plate (standard cradle) – GA1013A
2
Front plates – GA1100*--
12
Neck pads (standard cradle) – GA1014B
3
Set Knobs and spindles– GA1008E
13
Complete standard cradle – GA1002F
4
Face shield – GA1007
14
Ratchet rear interface – GA1067
5
Ocular Visor - GA1006
15
Ratchet net – GA1012F
6
Inner shell – GA1003H
16
Ratchet front interface – GA1066
7
Impact cap / rigid padding – GA1024
17
Ratchet headband– GA1065
8
Comfort soft padding – GA1005C
18
Complete ratchet cradle – GA1002N
9
Net (standard cradle) – GA1012K
19
2 points chinstrap – GA1009Q
10
Headband (standard cradle) – GA1011C
20
Chincup – GA1016B
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Fire-fighting Helmets / Preventive care, control
and maintenance
F1E Helmet
F1E helmets (large size, 59-65 cm) were delivered between 2001 and 2010
They are fitted with a standard harness or a ratchet harness (since 2002)
F1E helmet components
1
Shell – GA0N1800 (nickel helmet)
GA0N1700-xx (painted helmet)
10
Harness straps (spider) – GA1052A
2
Front plate – GA1100*
11
3 pts chinstrap (ratchet) – GA1009M
3
Kit Fix (pair) –GA1045
11b
2 pts chinstrap (standard) – GA1009H
4
Multifix – GA1013E
12
Chincup (standard) – GA1016B
5
Face shield + carrier – GA1051A
13
Headband + net (standard) – GA1049
6
Impact cap (rigid) – GA1048
14
Neck plate (standard) – GA1013A
7
Inner shell – GA1047
15
Neck pads (standard) – GA1014B
8
Ocular Visor– GA1046A
16
Complete standard cradle – GA1002L
9
Ocular visor lever – GA1063
17
Ratchet harness F1E – GA1002M
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Fire-fighting Helmets / Preventive care, control
and maintenance
F1 SF15 Helmet – Version EN 443:1997
F1SF helmets (headsize 50-63 cm) have been delivered since 2005 (till June 2011)
They are fitted with a standard cradle or a ratchet cradle.
F1SF helmet components
1
GAN2300*- Shell (painted helmets)
GAN2400* -Shell(nickel helmets)
13
GA1009R – Complets Chinstrap
2
GA1100* - Front plate
14
GA1463 – Chinstrap support (pair)
3
GA1050 – Set of pins and knobs for visors
15
GA1016B – Soft chincup
4
GA1073 – Kit Fix (pair)
16
GA1012 L – Standard cradle Net
5
GA1461 – Interface for accessories (paire)
17
GA1011C – Standard cradle Headband
6
GA1007 / GA1007C / GA1007E – Face shield
18
GA1013A – Standard cradle rear plate
7
GA1006 – Ocular screen
19
GA1014B –Standard cradle neck pads (pair)
8
GA1003J – Inner shell
20
GA1002S – Complete standard cradle
9
GA1058 – Rigid inner padding
Or
10
GA1005K – Soft comfort padding
21
GA1067 –Ratchet Cradle rear interface
11
GA1074 – Chinstrap and neck curtain fixture
22
GA1012F – Ratchet cradle Net
12
GA3227 – Chinstrap rear interface
23
GA3225 – Ratchet cradle front interface
24
GA3223 – Complete Ratchet Cradle
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Fire-fighting Helmets / Preventive care, control
and maintenance
F1E – version EN443:2008
F1E EN443:2008 helmets (big size, 59-65 cm), delivered since 2008.
Equipped with a ratchet cradle, only available as painted version.
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F1E – EN443 :2008 Components
1
Shell – GA0N1700-xx
9
Ocular screen– GA1046A
2
Front plate – GA1100-xx
9b
Ocular visor lever – GA1063
3
Kit Fix (pair) –GA1045
10
Harness straps (spider) – GA1052A
4
Multifix – GA1013E
11
3 point chinstrap (ratchet) – GA1009M
5
Faceshield+carrier
- GA1055C (gold)
- GA1055B (clear)
12
Ratchet cradle F1E – GA1002M
6
Reinforced rigid inner padding – GA1079
13
Aluminized neck curtain – GA1106R
7
Soft comfort padding – GA1005K
14
Integral neck curtain – GA1106P
8
Inner shell – GA1047
10
Dessins non contractuels
1 2
3
4 5
6
7
8
9-9b
10
11
12
13
14
3
Fire-fighting Helmets / Preventive care, control
and maintenance
F1 SF25 – Version EN443:2008
F1SF EN443:2008 (50-63 cm), delivered since 2008.
Equipped with a ratchet headband, available as painted or metalized version.
2
1
11
3
4
12
5
13
16
7
6
8
14
9
15
10
17
18
20
19
Dessins non contractuels
F1SF – EN443 :2008 Helmet components
1
Shell - GA0N2300-BR (metalized)
- GA0N2300-xx (painted)
11
Chinstrap and neck curtain interface – GA1074
2
Front plate – GA1100*--
12
3 point chinstrap – GA3226
3
Set of knobs and spindles for visors – GA1050
13
Chinstrap support (pair) – GA1463
4
Kit Fix (pair) – GA1073
14
Soft chincup – GA1016B
5
Accessory interface (pair) – GA1461
15
Ratchet cradle rear interface – GA3227
6
Faceshield – GA1007I (gold)
- GA1007J (clear)
16
Ratchet cradle net – GA1012F
7
Ocular screen – GA1006
17
Ratchet cradle front interface – GA3225
8
Inner shell – GA1003J
18
Complete Ratchet cradle – GA3223
9
Reinforced rigid inner padding – GA1078
19
Aluminized neck curtain – GA1109
10
Soft comfort padding – GA1005K
20
Integral neck curtain – GA1110
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Fire-fighting Helmets / Preventive care, control
and maintenance
CONFORMITY CRITERIA OF F1 COMPONENTS
s procedure
The control must be performed in the order described below.
Before proceeding with the control, make sure that the helmets is equipped with all original
parts. Then, proceed as described in the following section.
List of conformity criteria
1) Control of the shell (all models)
Definition of the shell areas
Horizontal plane (axis
used for visor rotation)
Lower area
(excluding lower
edges)
Upper area
Nickel shells (F1, F1S, F1E, F1SF)
1-1 – Upper area
(above the horizontal plane in the above figure) :
• if light scratch or small star pattern, the shell is conform,
if nickel (or paint) is loose
(unstuck) on ≥4 cm² (single piece) : replace the shell
if nickel (or paint) is missing
on ≥1 cm² (single piece) : replace the shell
1-2 – Lower area
below the horizontal plane on the above figure :
if nickel (or paint) is missing
on ≥4 cm² (single piece) : replace the shell
1-3 – Complete shell (all models)
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Fire-fighting Helmets / Preventive care, control
and maintenance
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Under certain especially severe operation conditions (training), with a combination of high
temperature, important heat flow and very charged fumes, the coating of the helmet could
change the aspect in a more or less strong way.
• If the shell is a little dirty / dingy, it is conform (it must be properly cleaned)
• If there are stains that cannot be removed when cleaning the shell (using Poli F1
for nickel shell) : replace the shell.
• If the shell (base material) is cracked / broken=existance of a line where nickel is
missing : replace the shell
• if the shell has been drilled (holes) for any reason (repair, addition of element) :
replace the shell
• If the shell is « bumped » on the outside, check inside if the distorsion can be felt.
If yes, replace the shell.
This inside control should be performed only if there is small areas (< 1cm2) of metal
or paint missing, or if there is a “star” pattern on the shell following an impact and the
helmet is conform to 1-1 and 1-2. Disassembling the helmet will then be necessary.
Painted shells (F1, F1S, F1E, F1SF) or Metalized (F1SF EN443:2008)
1-1 – Upper area
(above the horizontal plane in the above figure) :
• if light scratch or small star pattern, the shell is conform,
if paint is loose
(unstuck) on ≥2 cm² (single piece) : replace the shell
if paint is missing
on ≥2 cm² (single piece) : replace the shell
1-2 – Lower area
below the horizontal plane on the above figure :
if paint/ metal is missing
on ≥4 cm² (single piece) : replace the shell
1-3 – Complete shell (all models)
Under certain especially severe operation conditions (training), with a combination of high
temperature, important heat flow and very charged fumes, the coating of the helmet could
change the aspect in a more or less strong way.
• If the shell is a little dirty / dingy, it is conform (it must be properly cleaned)
• If the shell (base material) is cracked / broken=existance of a line where the
varnish is missing : replace the shell
• if the shell has been drilled (holes) for any reason (repair, addition of element) :
replace the shell
• If the shell is « bumped » on the outside, check inside if the distorsion can be felt.
If yes, replace the shell.
1-4 – Inserts for chinstrap and inner shell attachment (F1 and F1S only)
The attachment device of the chinstrap and the inner shell on the shell includes inserts on
the lower edges of the shell (fixed by ultrasonic welding) where is mounted the element used
to connect the pression stud of the chinstrap.
1-4-1 Chinstrap inserts
• If the insert gets loose : it is possible to re-glue it once using cyanoacrylate glue or
with heat.
• If it becomes loose a second time: change the shell.
1-4-2 Inner shell inserts
Fire-fighting Helmets / Preventive care, control
and maintenance
• Same procedure as 1-4-1.
Caution : losing an insert can occur after a strong impact / shock on the helmet. It is then
strongly recommended to inspect carefully the helmet and the shell.
1-5 – Mask attachment (F1 and F1S)
If the mask attachment is cracked, broken or unclipsed : replace it (use silicon
when installing the new hearing plate)
1-6 – Front plate (all models)
If the front plate is getting dirty, it is not necessary to change it, except for aspect issues.
2) Control of visors, axes and knobs (all models)
Definition of face shield areas
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Sensitive area of F1 face shield (A and C)
d
d
d
d
area A (d = 1cm)
Lower and upper
rims = area C
Ocular area (band) (B)
Band B (3 cm)
Fire-fighting Helmets / Preventive care, control
and maintenance
2-1 Control of face shield
If there are clouds of large stains (loss of metal coating diameter > 1mm) on
area A : replace the face shield. Typical due to exposure to exhaust gases
(failure #1).
If there are lots of small size stains (absence of metal coating ≥ 1 mm) on area
A, replace the face shield. Typical due to strong exposure to humidity.
If there is a large stain (absence of metal coating > 2 cm2) in the band B of 3 cm
around level of the eyes : replace the face shield (failure #2).
If there is a loss of metal coating (≥ ½ cm wide) on one of the two rims of area
C : replace the face shield (failure #3)
If the face shield is cracked, broken or distorted because of heat exposure :
replace the face shield.
The figures below show the different types of default above mentionned (1, 2, 3) :
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1
2
3
Failure #2 : large stain on band B
Failure #3 : absence of coating on area C
Failure #1 : stains on area A
2-2 Control of Eye-guard (ocular screen)
If visibility is reduced (scratches, stains, etc.) : replace the eye-guard
If the eye-guard is cracked or broken : replace the eye-guard
2-3 Control of axles, spindles and knobs (F)
• Check that all components are present,
If the mechanism remains too tight or too loose after adjustment : replace
axes, spindles and knobs.
Important (F1 helmet only) : when unassembling the rotation kit for the first
time, the following elements should be upgraded with new ones :
• Axles pin : replace the plastic pin with a metal one
• Washer : replace the metal washer by a waterproof one
Fire-fighting Helmets / Preventive care, control
and maintenance
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3) Control of inner shell and inner elements
3-1 Control of inner shell (all models)
If the inner shell is distorted, cracked or broken (particularly next to the
attachment screws and washers) : replace the inner shell
Replace any missing screw
• Note : there is an insert in this area (see 1-4-2)
3-2 Control of cradle (all models)
Headband = check its overall condition, and control the 5 velcro straps are ok.
If not, replace the headband (standard headband).
Headband support = check that the 6 mounting clips are ok and conform. If not,
replace the cradle (standard headband).
Net = if the net is torn or damaged, replace the cradle net.
Ratchet headband = check condition of the leather and the proper function of
the adjustment mechanism. If damaged, replace the ratchet cradle
3-3 Control of rigid padding (F1S, F1E, F1SF)
if the padding is broken, cracked or damaged : replace the padding.
3-4 Control of inner padding (all models)
if the padding is torn, damaged : replace the inner padding.
On EN443 :2008 helmets (F1E, F1SF), with reinforced inner padding :
if the reinforcement complex has become loose (in a way it is affecting its
correct ficture on the rigid inner padding): replace the inner padding.
3-5 Control of the neck pad fixture (standard cradle)
• if it is cracked or broken, especially on the clip position : replace the fixture
• if any of the clips is missing : replace the fixture
3-6 Control of the neck pads (standard cradle)
• If they are torn, flat or damaged, reducing their shock absorbtion capability :
replace the neck pads.
3-7 Control of cheek pads (F1 / F1S)
• If missing or detached from the helmet : stick them (neoprene glue) after careful
cleaning of the shell.
• If they do not stick properly or if they have dried out, shock absorbtion is reduced :
replace the cheek pads.
3-8 Control of chinstrap / chincup (All models)
• If one end of the chinstrap is damaged or missing : replace the chinstrap (F1 and
F1S).
Fire-fighting Helmets / Preventive care, control
and maintenance
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• If one of the clips is broken : replace the chinstrap (F1 and F1S)
• If the chinsrap is torn or damage : replace the chinstrap (all models)
• If the chincup is cracked or broken : replace the chincup (all models)
•
If the chincup has dried, softened : replace the chincup (all models)
3-9 Control of fixation interfaces (F1SF, F1E)
y If the interfaces (chinstrap, neck curtain, cradle, accessories) are cracked or broken :
change the relevant interface (F1SF)
y If the Multifix interface is cracked or broken : change the multifix (F1E). Verify
presence and right positioning of the pin.
IMPORTANT
: Points 3.1 to 3.4 can occur after an important shock on the helmet. A
complete ckeck should then be performed.
4) Important Remark
For all options mounted on the helmet (neck curtain, lamp fixture, communication
system, etc.) : check their attachment to the helmet, including the condition of the
parts used for it.
Fire-fighting Helmets / Preventive care, control
and maintenance
ADJUSTMENT OF THE HELMET
Adjusting the cradle to the user’s head is a key step to provide the proper level of comfort
and protection.
Standard Cradle
1st setting 2
nd
setting
First setting : Headband adjustment
• adjust the headband to the correct size
• The angle of 30° should be checked
• The helmet shall not fall even without chinstrap
• Face shield shall not touch the nose / face
• Ocular screen shall not « cut » the nose
Second setting : Depth adjustment
• This point is critical if the helmet is worn with a helmet mounted mask.
Ratchet Harness
First setting : preset the headband
S : Headsize < 55 cm
M : Headsize between 55 and 59 cm
L : Headsize > 59 cm
Second setting
: Adjust the headband (helmet on the head)
Tighten : Pull (a) in
Release : push (b) et push (a) out
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Fire-fighting Helmets / Preventive care, control
and maintenance
REPLACEMENT OF SPARE PARTS
GUIDELINES
Required Equipment
y 1 cross screwdriver and 1 flat screwdriver TOM Pouce (F1, F1S)
y 1 Torx screwdriver 15 (F1E)
y 1 Torx 20 screwdriver (F1SF)
y 1 small flexible clamp, 1 tightening device
y 1 tube of cyanolite glue (for inserts, F1 and F1S)
y 1 tube of neoprene glue (foams)
y 1 tube of silicone (seals / orings)
y F gasoline (to clean the glue)
y desinfecting wipers
F1/F1S helmet
Follow carefully the order to disassemble the helmet until you
reach the part to change.
Reassembling will be performed using the same order.
1) Chinstrap (E) and chincup (F)
With the screwdriver, use leverage effect on the stud (push on
the shell) to unlock fixations with risking of deteriorating
inserts.
The chincup can be slided out of the chinstrap by its end.
2) Neck plate (I)
Untight the 2 net straps (a), then unlock the neck plate (b) with
its neck pads pulling on the 2 sides.
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Fire-fighting Helmets / Preventive care, control
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3a) Standard Cradle
Take out the cradle by unlocking first the front and rear clips
from their locations, then taking out the side clips which
locating groove is larger.
Always start with side clips when reassembling the cradle.
The headband can be unlocked with the velcros.
3b) Ratchet cradle
Unlock the cradle on the front (2 points – a) and on the rear (2
points – b)
4a) Soft padding (L)
Remove the padding carefully to avoid tearing it.
When re-installing the soft padding, place the smaller / thinner part in the front, the 2
centering blocks of the rear must be placed inside the shell comb. The correct position is
reached when the rear part is positioned on the edge of the inner shell.
4b) Rigid padding
Check the padding is not «glued » by the silicon of the ear
plates. If this occurs, cut the silicon using a cutter.
Remove the padding using the inner shell on the side. Open
the shell to remove the padding easily.
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5) The inner shell (M)
Once the padding is out, the inner shell can be taken out by unlocking the 2 screws, and
pressing it out.
Be careful with the repositionning of the inner shell when reassembling it. Do not forget the
washers and do not tighten the screws too much.
6) Visors (face shield and ocular screen)
Face shield (a), ocular screen (b) and axles (c) can easily be unassembled :
1. Remove both left and right spindles (c) with a screwdriver
2. remove the right knurl (the one with lever) and remove the round axle from the inside
(lever is in high position when screen is inside the shell)
3. untighten the left knob and take the square axle out
4. take the ocular screen out by pressing it slightly
5. Take the black space washers (the longer piece (d) that serves as visor stopper in the
upper position is located on the right side)
6. Take out the face shield with care to avoid scratching
7. remove the white washers (waterproofness) from the shell.
7) Front plate:
It is attached to the shell with 2 or 4 screws, depending on the
model.
It can be taken out before the visors, protecting properly the
face shield with soft tissue.
The helmet is now totally disassembled.
Only cheek pads and ear plates are still attached to the shell.
If the ear plates are disassembled, they need to be replaced. For assembly, put three points
of silicone at the connection of the helmet shell and fixation points.
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Fire-fighting Helmets / Preventive care, control
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F1E Helmet – Specific operations
Face shield installation
Put the spring (e) in the screen axle of the fixture (f) to clip
it on the shell (g) respecting the guiding plots (h).
Tighten the fixture with a 4x5 torx screw
Check operation moving the visor up and down
Slide in the PU padding positionning first the left side (front
plate on the right)
Ocular screen and inner shell installation
Position the ocular screen (b) on the inner shell (d).
Position the hole on the Ondiflex washer (c) to the inside.
Add the nylon ring (a).
Tighten a 4x5 torx screw in the inner shell insert.
Same operation on the other side
Clip the chinstrap in the inner shell (buckle on the left side)
Position the inner shell in the shell between the face shield
and the PU padding.
Attach the inner shell with M4x8 Dacromat screws.
The 2 inner shell «ears» must be positionned in the 2 shell
grooves.
Installation of the harness (spider)
The wider part of the leather is aiming at the front part of the
helmet. Slide the strap under the attachment point. Clip the
attachment point in their groove (2 on the inner shell front
side, 2 on the inner shell sides, 2 on the rear part of the
shell. Make sure click is well performed.
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Fire-fighting Helmets / Preventive care, control
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Chinstrap installation
Unassembling
: Rotate the strap by 180° (a), pull (b) out of
the location (c). Unlock the buckle to take the chinstrap out
of the rear point.
Assembling
: Put the clip in its location (a) and pull (b)
Attach both parts of the chinstrap with the rear strap sliding it
through the multifix fixture.
Caution : the chinstrap strap must go under the (spider)
harness
Installation of the ratchet cradle
Clip the red cradle tensionning device in the multifix fixture (2
points) at the rear of the shell.
Clip the ratchet headband in its locations (front in the inner
shell, rear in the red tensionning device).
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Fire-fighting Helmets / Preventive care, control
and maintenance
ASSEMBLY PROCEDURE FOR F1SF HELMET
Processing the operations in the correct sequence is necessary for a successful assembly of
the product.
Unassembling the helmet should be processed in the exact opposite order. All symetric parts
(chinstrap supports, accessory interfaces, kitfix) are marked D(Droite=Right) and G
(Gauche=Left).
Assembly of visors
References GA1006 – Oculaire Screen EN166
GA1007 – Face shield 9% (or GA1007C or GA1007E)
GA1050 – Set of pins and knobs for visors for F1SF
Make sure the visor is free of scratches
Position the waterproof washers.
Position the face shield
Place a washer on the tightening nut side and put a visor clip on the opposite side
Place the ocular screen and slide through the threaded axle on the washer side
1. Screw the nut on the threaded axle
Using clamps, put the stainless steel spindle in the tightening nut
Place the square axle on the clip side, put the lever next to the clip and put a stainless steel
spindle in the lever using clamps.
Breakout view of the visor mecanism (pins, axles and knobs)
Assembly of inner shell, chinstrap and interfaces
It is recommended to assemble both sides one after the other.
Kit Fix assembly
Position the Kit Fix edge in the shell groove and slide the axle through the hole in the shell.
Repeat for the other side.
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Kit Fix positionning on the shell side
Assembly of accessory interfaces (lamp interface)
References
GA1461 – Interfaces for accessories (L+R)
1. Place the interface in front of the attachment points in the shell (step 1)
2. Insert the rear attachment until you can clip the front part (steps 2 and 3).
3. Check the interface and the shell are well secured (step 4)
4. Repeat for the other side.
Step 1 :
Step 2
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Step 3
Step 4 (inside view)
Inner shell assembly
References GA1003J – F1SF Inner shell
GA1463 – Chinstrap supports (L+R)
GA1009R – Chinstrap F1SF (3 points)
GA1074 – Chinstrap and neck curtain fixture
1. Position the inner shell in the kit fix axles that show inside the helmet shell
2. Position the chinstrap attachment points (L and R) inside the chinstrap supports (1-right
and 2-Left) in the position #2 front the lower edge.
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Positionning the Chinstrap
in the support parts
Adjustment of the angular position of the chinstrap
1
2
Position #2
(from below)
Fire-fighting Helmets / Preventive care, control
and maintenance
Assembly of the chinstrap in the helmet shell
1. Attach the chinstrap supports inside the shell (Steps 1 et 2) checking they are
properly locked (step 3).
2. Attach the support to the Kitfix inserts with M4x12 screws (step 4). Securely tighten the
screws, but don’t overtighten (orientative torque 2,8 Nm).
Step 1
Step 2
Step 3 (side locking)
Step 4 : screw in Kit Fix
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Install the Chinstrap and neck curtain fixture to the shell inserting the 2 lower edges in
the shell clips
Inner paddings assembly
Rigid padding installation (PU)
References GA1058 – Rigid padding F1SF
GA1005K – Comfort padding F1SF
1. Position the rigid padding (step 1).
2. Push it towards the shell to lock it in its position (step 2).
Step 1 : positionning
Step 2 : Locking
Comfort padding assembly (PE)
Position the comfort padding and lock it under the clips used for cradle attachment.
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Cradle assembly
Ratchet Cradle
References GA3223 – F1SF Ratchet Cradle
GA1067 – Rear interface for Ratchet Cradle
GA3242 – Front interface for Ratchet Cradle
Insert the 2 front clips (front interface) in the inner shell slots, the 2 other clips being located
under the slots (height adjusment is made using these 2 lower clips)
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Insert the 2 external clips and the 2 centering pins of the rear interface in the 4 slots in the
shell (rear side). Make sure the centering pins are behind the and the unlocking buttons are
in front.
Insert the chinstrap rear interface in the chinstrap / neck curtain fixture (insert
and pull to lock) and position the neck pad in front of the interface attaching it
to the cradle with the velcro straps.
Clips to insert
Slide the clips to the
bottom of the slots
Neck pad
Chinstrap rear
interface
Fire-fighting Helmets / Preventive care, control
and maintenance
CONFORMITY CRITERIA FOR F2 COMPONENTS
Control procedure
The control should be performed following the order mentioned below.
Before proceeding, check that the helmet includes only original / Gallet parts.
Components of F2 helmet
1
Shell – GA3002
4
Complete F2 cradle – GA3005
2
PSE padding - rigid – GA3015
5
Complete F2 chinstrap – GA3003
3
PE padding - soft – GA3011
6
F2 Protection goggles – GA3007
List of conformity criteria
1) Helmet Shell
If the shell is cracked : change the shell,
If the shell has been drilled during a previous repair operation or to add a non
certified element : change the shell,
If there is a significant bump on the shell (that can be felt from the inside) : change the
shell
.
If paint is missing on more than 1 cm
2
(single piece): change the shell.
2) Rigid inner padding (PSE)
If the padding is cracked or broken : change the padding.
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3) Soft inner padding (PE) :
If the padding is torn : change the padding.
Check the 6 ends of the padding, where it is attached to the shell. If the
attachment points are damaged : change the padding
4) Cradle
If the net is torn : change the net
If there are damaged or missing clips on the headband : change the headband.
If the leather is damaged / torn on the headband :
change the headband
If the rear interface is damaged, if one of its clips is damaged or missing :
change the
interface
If the adjustment part of the headband is damaged :
change the headband
5) Chinstrap
If the chinstrap is torn : change the chinstrap
If the locker at the end of the strap is broken or missing : change the chinstrap.
6) Orange Fire goggle
If the silicon lace is broken or too loose : change the lace
If one of the attachment on the goggle is damaged : change the goggle
Warning : when the F2 helmet is stored, the goggle must be stored inside the helmet shell and not
left on the top (standby position). This would result in loosening and eventually damaging the lace
and reducing the protection..
Disassembling the F2 helmet
Follow the proper order of operations to reach the part that needs to be replaced.
Place the goggles (6) on the top of the shell, unlock the chinstrap to have an easy access to
the internal parts.
Remove the complete harness (4) attached to the shell by 6 clips (4 on the headband and 2
on the rear interface).
Remove the soft padding (3) and the rigid padding (2)
Control the chinstrap (5) and, if needed, remove it.
Control the goggles (6) and, if needed, remove them.
Re-assembling the helmet will be performed in the exact opposite order.
Warning : to reassemble the cradle, always start with the 2 front clips.
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CONFORMITY CRITERIA FOR
F2
X-TREM COMPONENTS
Control procedure
The control should be performed following the order mentioned below.
Before proceeding, check that the helmet includes only original / Gallet parts.
1. F2 X-TREM shell
GA3220
2. Shell straps GA3222
3. Ratchet cradle GA3223
dont
4. Headband GA3224
5. Rear Interface GA3227
6. Net GA1012F
7. Front Interface GA3225
8. Chinstrap GA3226
• Remove the neck pads to release the chinstrap attachment (change the neck pad if
unsewed and/or torn.
• Open the chinstrap to access the inner elements
• Release the rear attachment of the chinstrap (push down and rotate 1/4)
Control the ratchet and chinstrap
Unlock the cradle (2 clips in the front, 2 clips in the rear)
If one of the clip is damaged : change the headband
If the headband is torn : change the headband
If the net is torn : change the net
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Remove the shell straps pulling the 4 clips off the shell (pull to the outside)
Remove the chinstrap pulling the 2 clips off the shell (pull to the inside)
Shell
Same control procedure as for a F1 painted shell.
Re-assembling the helmet
Assemble the shell straps and the chinstrap
Pre-position the chisntrap interface at the rear, it will be used as a guide for the complete
reassembling procedure
Attach the 4 straps clips (the shortest straps are in the front)
Attach the chinstrap clips, leaving the adjustment points on the outside
Check the straps are not twisted, the chisntrap lower strap being inserted into the shell straps
center.
Remove the chinstrap rear interface and insert the ratchet using the clips (rear and front)
Place the chinstrap interface between the headband and the neck pad and attach it to the
shell. Install the neck pad to lock the chinstrap.
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