Fast Ballistic High Cut User manual

FOR FAST BALLISTIC
AND CARBON HELMETS
HELMET OPERATOR’S MANUAL
© OPS-CORE 2016 06-05-160 REV. B

HELMET VERSIONS
SIDE PAD TOP PAD TOP PAD REAR PAD
FAST BALLISTIC
HIGH CUT
FAST CARBON
3
/
4”
1
/
2”
3
/
4”
FAST HELMETS
This manual is specific to the following helmet models: FAST Ballistic High Cut, FAST Ballistic Maritime
and FAST Carbon.
FAST Ballistic High Cut Helmet is used for reference drawings throughout this Operator’s Manual.
If there are any procedure discrepancies due to other helmet versions they will be specifically noted.
ALL HELMET VERSIONS INCLUDE:
(2) SIDE PADS, (2) 1/2” TOP PADS, (2) 3/4” TOP PADS, (1) 1/2“ REAR PAD, (1) 3/4” REAR PAD
FAST BALLISTIC
MARITIME
1
/
2”
WING-LOC
ADAPTER (1)
SKELETON SHROUDPICATINNY
ADAPTER (1)
2

4
5
6-7
8
9-15
23-26
16-22
27
28
TABLE OF CONTENTS
HELMET COMPONENTS
SIZING GUIDE
PRO SETUP
CHINSTRAP OPERATION
WARNING & WARRANTY
OPERATOR NOTES
MAINTENANCE SCHEDULE
REPLACEMENT KITS
REPLACEMENT FITBAND COMFORT PADS
REPLACEMENT FITBAND & EPP PADS
REPLACEMENT EXTERIOR VELCRO
REPLACEMENT SKELETON SHROUD
REPLACEMENT FAST SIDE RAILS
ACCESSORY INTEGRATION
COUNTERWEIGHT & HELMET COVER
SKELETON SHROUD
FAST SIDE RAILS (ARCs)
EXTERIOR VELCRO®
SIDE COVERS & GUNSIGHT MANDIBLE
COMMs HEADSET
HELMET PART NUMBERS
REPLACEMENT PARTS / ACCESSORIES PART NUMBERS

HELMET COMPONENTS
4
Fitband
Top EPP Pad
Front EPP Pad
Rear EPP Pad
Side EPP Pad Side EPP Pad
Comfort Pad
Occ-Dial
Adjustment Knob
Integrated Retention System
(LED Version Available)
Skeleton Shroud
Helmet Shell
Exterior Velcro
Ballistic Screws
& T-Nuts
Bungee FAST Side
Rail (ARC)
Note: LED = Left Eye Dominant

SIZING GUIDE
HELMET SIZING GUIDE
X-LARGE
FAST HELMET SIZE CHINSTRAP SIZE (in)
S/M MEDIUM
M/L
L/XL
LARGE
XXL X-LARGE 27.5-30.5
27.5-30.5
26-29
24.5-27.5
CUSTOM FIT COMBINATIONS
Your FAST Helmet can be custom fit
with an alternate chinstrap size upon
ordering or a replacement chinstrap
can be purchased separately.
CHINSTRAP SIZING GUIDE
S ince people have different shaped heads, helmet size (the size
of the top of your head) is not always proportional to the chinstrap
size (the size of your face).
12
13 14
15 16
17 18
19
2 0
13
14 15
16 17
18 19
2 0
2
1
RUN MEASURING
TAPE ALONG FRONT
EDGE OF EAR
S/M HELMET WITH
LARGE CHINSTRAP
L/XL HELMET WITH
MEDIUM CHINSTRAP
FAST HELMET SIZE
Head Circumference (cm)
Head Circumference (in)
Head Size (US)
53 - 56
20⁄ - 22
S/M
up to 7
56 - 59
22 - 23¼
M/L
up to 7⁄
59 - 62
23¼ - 24⁄
L/XL
up to 7⁄
62 - 64.5
24⁄- 25⁄
XXL
up to 8⁄
5
FAST helmets have been designed from the ground up to t the largest group of users in helmet
sizes that most closely match their heads. However, there is still a small percentage of users that
will not t our standard sizing congurations. Please use the sizing guide below to determine your
helmet size and your chinstrap size. If you require a non-standard chinstrap/helmet conguration,
custom solutions are available.

FAST Helmets were designed for professionals who expect the most from their equipment. Just like
fine-tuning the suspension on a racecar or sighting in a fire-arm, the helmet must be set up properly
before use to function correctly. If you do not follow these instructions, your helmet will not function
in accordance with stated performance.
PRO SETUP
HEIGHT ADJUSTMENT
•The distance from the top of the eyebrow to the bottom of the
fitband should be approximately 0.5”- 1”. There should also be
enough room around your ears for COMMs / hearing protection.
•If the helmet sits too low on your head, remove the ½” top pads
and install the ¾” top pads.
•If the helmet sits at an uncomfortable angle, adjust the top pads,
or use a combination of ½” and ¾” top pads until it sits correctly.
ADJUST THE TOP PADS
•Put the helmet on. ½” pads come pre-installed
in the helmet. Turn the dial to loosen the fitband
so that all of the helmet weight is resting on top
of your head.
•With the fitband loose, check how high / low the
helmet is sitting. Forehead pad should be above and
not resting on the bony ridge of your eyebrows.
0.5”-1”
ADJUST THE REAR PADS
•Install the ¾” rear pad. Put the helmet on.
•If you feel uncomfortable pressure on your forehead,
take the ¾” pad out and put in the ½”pad.
•If it feels the same as with the ½” pad (can’t notice
the difference) then keep the ¾” installed. This will
make the helmet more stable and comfortable.
ADJUST FITBAND HEIGHT
•Put the helmet on and turn the dial to tighten
the fitband until it feels secure. Look up at the
sky. If the dial digs into your neck, it is too low.
•You can adjust the height of the dial by sliding
the rear fitband liner tabs that attach it to the
inside of the shell up and down.
•Set the dial at the height that is most
comfortable for you.
6

“PRE-LOAD” THE FITBAND
•You can set the shape of the fitband to
match the shape of your head for long
term comfort.
•Push or pull the rear fitband liner tabs
(used for height adjustment in step 3)
to adjust the fitband tension from a
round to more oval shape.
•Hold each rear fitband liner tab with
your hand in the location that sets the
fitband tension in the optimal shape
and then tighten the back screws to lock
the tabs in place.
INSTALL THE SIDE PADS
•Install the side pads onto the Velcro patches
on the inside of the helmet. These pads
make the helmet more stable and increase
protection from side impacts.
•If they feel tight or uncomfortable, try to
relocate them into a position that feels good.
Note: Check that all screws
and accessory hardware are
tight and secure.
YOUR HELMET IS
READY FOR USE!
TIGHTEN BACK SCREWS
•Tighten the back screws to lock the
rear fitband liner tabs, chinstrap and
side rails permanently in place.
•If you don’t do this, all of the
adjustments you just made will slip
and the helmet will likely come apart.
7

With both hands, pull the two Rear
Head-Loc®Sliders on the lower webbing
straps toward your chin until snug.
Note: The technique works best if
you only hold the plastic sliders
and don’t touch the webbing.
With both hands, pull the two Front
Head-Loc Sliders on the webbing straps
that come from the front temples of the
helmet toward your chin until snug.
8
Put the helmet on and fasten
the Chinstrap Buckle. Turn the
Occ-Dial Adjustment Knob to
tighten the fitband until it is
comfortably snug.
CHINSTRAP OPERATION
Occ-Dial
Adjustment Knob
Rear
Head-Loc
Slider
Front Head-Loc Slider

9
NIGHT OPERATIONS AIRBORNE OPERATIONS
BREACHING / ATV
MISSION DOCUMENTATION
Bungee
IFF Strobe
Counterweight
NVGs
IR Illuminator O2 Mask
Goggles
COMMs Headset
COMMs Headset
Video
Camera Video
Camera
HMD
Counterweight
Ballistic
Mandible
Side
Armor
Ballistic
Visor
There are three ways of attaching accessories to the FAST Helmet. The Ops-Core Skeleton Shroud or
VAS Shroud, FAST Side Rails (ARCs), and Exterior Velcro. These three components provide convenient
and secure ways to quickly attach and detach various accessories to different positions, and allow for
personalized customization.
RECOMMENDED CONFIGURATIONS
There are numerous accessories that can be attached to your FAST Helmet to be used in a variety of
situations. Below are some recommended congurations.
ACCESSORY INTEGRATION
Skeleton Shroud
FAST Side Rail (ARC)
Side Exterior
Velcro
Rear Exterior
Velcro
Top Exterior Velcro

COUNTERWEIGHT & HELMET COVER
COUNTERWEIGHT ATTACHMENT
REMOVE REAR SCREWS
Remove screws and T-nuts at back of FAST Side Rails.
Align the anchor of Counterweight to the holes on the rear
of the FAST Side Rail. The Rear Exterior Velcro will hold
Counterweight in place. Use your ngers to loosely attach
a screw to the Counterweight and FAST Helmet. Be sure
to place screw through Counterweight Anchor, Side Rail,
Helmet Shell, Fitband and Chinstrap Anchor. Repeat for
the opposite side.
SECURE COUNTERWEIGHT
Use a screwdriver to tighten all screws from the outside
of the Counterweight, making sure the Counterweight is
securely fastened to the rear of the FAST Helmet.
Note: Adding weight to helmet increases risk of
neck strain and injury. Only add counterweight
when absolutely necessary to balance loads on
front of helmet.
COUNTERWEIGHT KIT
The Counterweight Kit Includes (1) Counterweight
Pack with (5) Lead Weights and (2) 24mm Screws.
HELMET COVER
The Helmet Cover protects the shell outer
surface while still providing the functionalities
of the FAST platform.
(Open View)
(2) 24mm Screws
Lead
Weight
Window for Mini
Glow Stick
Anchor for
Side Rail
(Closed View)
FAST
Side Rail
Rear
Exterior Velcro
The Counterweight Kit reduces neck fatigue on long missions with night vision goggles or other accessories
that add weight to the front of the helmet. The Helmet Cover provides a variety of camouage options for
different environments.
10
Rear Pouch
Goggle
Retention
Flap
Velcro
Detachable Rear Pouch
Fits ANVIS Battery Pack

SKELETON SHROUD & VAS SHROUD COMPATIBILITY
Helmet Compatability
Fits the standard MARSOC / WARCOM 3-hole NVG mount pattern
NVG & Mount Arm Compatability
Ops-Core NVG Shrouds are compatible with the following combinations of night vision goggle and
mount arm styles:
MOUNT ARM
PVS-7B/7D
PVS-14
PVS-15
PVS-18
PVS-21
PVS-23
PVS-7A/7C
LUCIE NVG
F5050
F4949
ANVS-6/9
US ARMY
STANDARD
#A3256368
WILCOX®
L4 G24
#28300G24
NOROTOS®
INVG
#1820010
NOROTOS®
AKA2
#1840010
WILCOX®
L4 G21M
#28300G21M
WILCOX®
L4 G25
#28300G25
WILCOX®
L4 G29M
#28300G29M
WILCOX®
L4 G01
#56500G01
WILCOX®
L4 G02
#56500G02
NVG STYLE
SKELETON SHROUD
The Skeleton Shroud provides a front mounting option
for video cameras, visors, illuminators, and night vision
goggles (NVG’s).
PULL TEST
Before attaching any NVG’s to the mount, give it a sturdy
tug in all directions to ensure it is properly secured.
ATTACH NVG MOUNTING ARM
Insert and anchor the top of the NVG Mounting
Arm underneath the top of the bracket as shown.
While pressing the arm’s release trigger, push
down to snap and lock the arm in place.

TOP RAIL RAIL CORNER BACK RAIL
Rail corner allows for
instant and secure snap-in
attachment of Para-Flite
and Carleton O2 masks
with O2 Single Strap Kit.
Goggle Swivel Clips,
attached to your choice
of goggles, can quickly
clip into the back rail
while allowing freedom
of rotation.
Picatinny
Adapter
Wing-Loc
Adapter
O2 Strap Kit 36mm Goggle Swivel Clips
FAST SIDE RAILS (ARCs)
4-Position FAST Side Rails (ARCs) are mounted to the sides of the
helmet to allow for quick yet secure donning or dofng of various
headborne accessories.
ARC ADAPTERS
The three adapters shown on this FAST Side Rail are
commonly used for attaching accessories to the FAST
Helmets: Picatinny Adapter (A), O2 Single Strap Kit (B),
and 36mm Goggle Swivel Clip Kit (C).
Top Rail can accommodate
Picatinny Adapters, which
connect devices compatible
with 1911 Picatinny Rail,
and Wing-Loc Adapters,
which provide a base to
mount a variety of headborne
accessories.
12

VELCRO ATTACHMENT
Apply hooked Velcro to the bottom of a device. Place device on top of the looped Velcro that is already
attached to the FAST Helmet. Cover top of device with additional hook Velcro to secure it into place.
Simply remove the device by pulling it away from the looped Velcro.
Note: Additional hook Velcro not included.
Top Exterior Velcro
Identity Patch
Additional Velcro IR Strobe
EXTERIOR VELCRO®
Exterior loop Velcro is attached at the top, sides, and rear of the
FAST Helmet. The loop Velcro allows for easy mounting of accessories.
13
TOP VIEW REAR VIEW
Rear
Exterior
Velcro
Counterweight

SIDE COVERS & GUNSIGHT MANDIBLE
The Up-Armor Side Covers and Gunsight Mandible are accessories that provide additional head coverage
that allows a user to quickly adjust the degree of protection to match different threat levels.
Frame flexes for
Rifle / Cheek Weld
Edge Profile Clears
Rifle / Cheek Weld
GUNSIGHT MANDIBLE
The mandible uses a combination of soft armor
and support frame technology to provide lower
face protection. It is designed to fold in half to
conveniently t into a rucksack. The exibility
allows a close cheek weld and causes minimum
interference with sighting shoulder weapons.
ATTACHMENT
The Up-Armor Side Covers, and Mandible attach to
the FAST Side Rails. Attachment is tool-less and takes
less than a minute. Follow the Up-Armor Side Cover
instructions below for attaching Mandible.
SLIDE FRONT SHOE IN PLACE
Slide the Front Shoe of the Side Cover into the front
of the top FAST Side Rail (ARC) as shown.
LOCK SIDE COVERS IN PLACE
Snap the back of the Side Cover into the rear FAST
Side Rail (ARC) and turn the Cam-Loc Handle
downward to lock into place.
Front
Shoe
Cam-Loc
Handle
UP-ARMOR SIDE COVERS
Up-Armor Side Covers are available in Ballistic
and Non-Ballistic versions. Both versions feature
a durable carbon ber exterior. The Non-Ballistic
version provides environmental protection, while
the Ballistic version is made from the same type
of materials as the FAST Ballistic helmet. *
* Note: Detailed threat performance specications are available at www.ops-core.com
14

15
RELOCATE TOP PADS
Position the top pads in the helmet so there is enough space for
the headband of the headset to sit in between them.
INSERT HEADSET HEADBAND
Flip the Comfort Pad / Fitband away from the front
impact liner and slide the headset headband around
it as shown. This will position the headset’s headband
on the outside of the helmet Fitband so that it does not
create a pressure point when you tighten the
Occ-Dial Adjustment Knob.
REATTACH FITBAND
Reattach the Comfort Pad / Fitband to the key-slots in
the front impact liner by bending the pad in the center
and pushing on the rivets (one at a time) with your
thumb while at the same time sliding them toward the
sides of the helmet.
COMMs HEADSET
Theliner system iscompatible with a variety of COMMs headsets and
hearing protection devices. Instructions for use with headband style
COMMs is below.
Front EPP Pad
Fitband Comfort Pad
DETACH FITBAND
Place your index nger behind the center
of the Fitband Comfort Pad and carefully
bend away from the Front EPP Pad as shown.
Pinch the Fitband Comfort Pad and use your thumb
to slide the pad sideways ½” towards the center of the
helmet along the Front EPP Pad. Repeat on both sides
until the pad is released from the key slots.
Note: Do not pull the Fitband Comfort Pad away
from the Front EPP Pad or you may break the
Front EPP Pad Key Slots.

RECOMMENDED MAINTENANCE: NATIONAL GUARD
•Replace all items on as-needed basis and based on inspection.
•Replace Exterior Velcro and repaint the shell after 4 years.
RECOMMENDED MAINTENANCE: ACTIVE DUTY
(Defined as soldiers who use their helmet 1440 hours/year or more)
•Replace Fitband Comfort Pads every 100 days or once/year.
•Replace Fitband, Chinstrap, Hardware, and EPP Pads after 2 years.
•Replace Exterior Velcro and repaint shell after 4 years.
•Replace other components if damaged / worn out as needed.
RECOMMENDED MAINTENANCE: ALL USERS
•Clean the helmet with a mild detergent and water.*
•Check that the chinstrap screws are tight using a athead screwdriver.
•Clean the Velcro for dust and dirt by using air pressure.
•Visually check the Skeleton Shroud or VAS Shroud and FAST Side Rails for signs of breakage.
•Visually check the Fitband for signs of breakage.
•Check that the Occ-Dial Adjustment Knob works properly.
•Check that the chinstrap does not have any damage and that the buckle latches and releases
properly.
*The whole helmet can be rinsed in fresh water.
Note: If any defects are found, the damaged components should be replaced
before use.
MAINTENANCE SCHEDULE
16

Exterior
Velcro
FAST Side
Rails (ARCs)
EPP
Pad Kit
Front
EPP Pad
Fitband Chinstrap & Hardware
Fitband Comfort Pads
Skeleton
Shroud Kit
Bungees Kit
Repaint Helmet Shell
REPLACEMENT KITS
17

Nape
Comfort Pad
Front
Comfort Pad
Left Side
Comfort Pad
Right Side
Comfort Pad
REPLACEMENT FITBAND COMFORT PADS
KIT INCLUDES THE FOLLOWING COMFORT PADS:
18
REMOVE OLD COMFORT PADS
Simply peel off all old comfort pads from the tband. A tband with all comfort pads removed should
look like the image below.
COMFORT PAD INSTALLATION
Attach the new comfort pads based on the instructions that came with the “Replacement Fitband
Comfort Pads Installation Instructions” manual.
Nape Comfort Pad
Front Comfort Pad
Left Side Comfort Pad
Right Side Comfort Pad

Fitband
Location
EPP PAD REPLACEMENT KIT
Install the pads onto the Velcro patches on the
inside of the helmet as shown. The Top and Rear
Pads come in two different thicknesses. Use the
pad that ts the best. See pages 6-7.
KIT INCLUDES THE FOLLOWING EPP PADS:
Side Pad Side Pad
Top Pad
Top Pad
Back Pad
REPLACEMENT FITBAND & EPP PADS
REPLACEMENT FITBAND:
The replacement Fitband kit
attaches to the Front EPP Pad.
Reassemble helmet as shown.
REPLACEMENT FRONT
EPP PAD KIT:
The Front EPP Pad is inserted
into the helmet shell before the
Fitband. It is held into the helmet
shell by Velcro patches.
Front EPP
Pad Location
19

PLACEMENT PREPARATION
Using the diagram to the right, carefully align Velcro
pieces to their proper positions. Test t all pieces before
removing backing. Adhesive on this Velcro is pressure
sensitive. Once in place it needs to be pressed down
rmly. Please allow up to 24 hours for adhesive to reach
maximum bonding strength.
KITS INCLUDE THE FOLLOWING REPLACEMENT PARTS:
REPLACEMENT EXTERIOR VELCRO
Slowly
Peel Back
CAREFULLY REMOVE OLD VELCRO
Note: It may be easier to remove Velcro by heating the helmet
shell to 70oc using a hair dryer. Do not heat helmet above 70oc
or helmet will be seriously damaged.
Using your ngers, carefully peel the Velcro away
from the helmet shell. DO NOT BRISKLY
RIP THE VELCRO OFF! Continue this
process by slowly pulling it back until all
Velcro is removed.
CLEAN THE HELMET SHELL
To remove excess adhesive from old Velcro and to ensure
optimal adhesion of new Velcro, gently rub affected areas
with a clean towel and Isopropyl Rubbing Alcohol. Do not
use harsh chemicals. If traces of adhesive remain, you can
use Goo Gone®to remove stubborn residue. Wipe the area
with alcohol again after use. Allow the helmet to dry before
attempting to place new Velcro onto the shell’s surface.
Rear
Exterior Velcro
Top Exterior
Velcro
Side
Exterior
Velcro
FAST High Cut FAST Carbon
FAST Maritime
Kit A Kit B