Fast WORM-DIAL User manual

WITH LUX LINER
HELMET OPERATOR’S MANUAL
© OPS-CORE 2016 06-05-170 REV. B
*Showing FAST Ballistic High Cut
with Lux Liner and Worm-Dial.

HELMET VERSIONS
FAST HELMETS
This manual is specific to the following helmet models: FAST Ballistic High Cut, and FAST Ballistic
Maritime, with pre-installed Lux Liner (H-Nape or Worm-Dial Versions).
FAST Ballistic High Cut Helmet with Worm-Dial and Lux Liner is used for reference drawings
throughout this Operator’s Manual. If there are any procedure discrepancies due to other helmet / Lux
Liner / Chinstrap versions they will be specifically noted.
PRE-INSTALLED LUX LINER KIT:
Pads are shipped in the standard configuration with nine installed pads. Pads can be placed in a variety
of alternate positions to achieve optimal comfort.
ALL HELMET VERSIONS INCLUDE:
ADDITIONAL PADS
(Also Included)
(1) Thin x2 Pad
(1) Thin x4 Pad
(1) Impact Liner
(1) H-Nape Chinstrap
(2) Thick x4 Pads
(2) Thin x2 Pads
(5) Thick x2 Pads
S/M KIT INCLUDES: M/L &L/XL KIT INCLUDES:
(1) Impact Liner
(1) H-Nape Chinstrap
(1) Thick x5 Pad
(2) Thin x2 Pads
(5) Thick x2 Pads
(1) Thick x4 Pad
(1) Impact Liner
(1) Worm-Dial Fitband
(1) Thick x4 Pad w/ Tabs
(2) Thin x2 Pads
(5) Thick x2 Pads
(1) Thick x4 Pad
S/M KIT INCLUDES: M/L &L/XL KIT INCLUDES:
(1) Impact Liner
(1) Worm-Dial Fitband
(1) Thick x5 Pad w/ Tabs
(2) Thin x2 Pads
(5) Thick x2 Pads
(1) Thick x4 Pad
ADDITIONAL PADS
(Also Included)
(1) Thin x2 Pad
(1) Thin x4 Pad
WORM-DIAL H-NAPE CHINSTRAP WORM-DIAL H-NAPE CHINSTRAP
FAST BALLISTIC HIGH CUT HELMET FAST BALLISTIC MARITIME HELMET
(1) WING-LOC ADAPTER (1) PICATINNY ADAPTER VAS SHROUD / SKELETON SHROUD (Optional)

4
5
6
7-8
9-15
23
16-22
24
TABLE OF CONTENTS
HELMET COMPONENTS
SIZING GUIDE
PRO SETUP
CHINSTRAP OPERATION
WARNING & WARRANTY
OPERATOR NOTES
MAINTENANCE SCHEDULE
REPLACEMENT KITS
REPLACEMENT WORM-DIAL FITBAND COMFORT PADS
REPLACEMENT CHINSTRAP & LUX LINER
REPLACEMENT EXTERIOR VELCRO
REPLACEMENT VAS SHROUD
REPLACEMENT FAST SIDE RAILS
ACCESSORY INTEGRATION
COUNTERWEIGHT & HELMET COVER
VAS SHROUD
FAST SIDE RAILS (ARCs)
EXTERIOR VELCRO®
SIDE COVERS & GUNSIGHT MANDIBLE
COMMs HEADSET

HELMET COMPONENTS
Integrated Retention System
(LED Version Available)
VAS Shroud
*Optional
Helmet Shell
Exterior Velcro
Ballistic Screws
& T-Nuts
Bungee FAST Side
Rail (ARC)
Note: LED = Left Eye Dominant
Lux Liner
(Showing Worm-Dial Version)
WORM-DIAL FITBAND
Impact Liner
H-NAPE CHINSTRAP
PAD CONFIGURATION:
1
2
3
4
(5) Top Pads
x4 or x5 Front Pad
(Row Quantity Depends on Lux Liner Size)
Rear Pad
Side Pad Side Pad
1
2
3
4
(5) Top Pads
x4 or x5 Front Pad
(Row Quantity Depends on Lux Liner Size)
Rear Pad
Side Pad
4

SIZING GUIDE
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.
HELMET SIZING GUIDE
X-LARGE
FAST HELMET SIZE WORM-DIAL FITBAND SIZE (in)
S/M MEDIUM
M/L
L/XL
LARGE
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). H-Nape chinstrap is one size fits all.
13
14 1 5
16 17
18 19
2 0
2
1
RUN MEASURING
TAPE ALONG FRONT
EDGE OF EAR
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⁄
S/M HELMET WITH
LARGE CHINSTRAP
L/XL HELMET WITH
MEDIUM CHINSTRAP
12
13 14
15 16
17 18
19
2 0
5

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 front of
the Lux Liner Impact Layer should be approximately 0.5”- 1”.
There should also be enough room around your ears for COMMs
hearing protection.
•If the helmet sits at an uncomfortable angle, adjust the top
pads or try using the Additional Pads provided in different
combinations (see step two “Additional Pads” for more detail)
.
1
2
3
4
(5) Top Pads
1
2
3
4
(5) Top Pads
ADJUST THE TOP PADS
•Put the helmet on. All Lux Liner Pads come pre-installed in the helmet.
Worm-Dial Fitband Users:
Turn the Worm-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.
•All Users: Forehead pad should be above and not resting on the bony ridge of your eyebrows.
0.5”-1”
ADDITIONAL PADS
•If the helmet feels tight or uncomfortable, adjust the Top Pads, and swap Thick x2 Pads out for
Additional Thin x2 or x4 Pad(s) try different combinations until helmet feels comfortable.
(1) Thin x4 Pad
(1) Thin x2 Pad
H-NAPE USERS WORM-DIAL USERS
6(1) Thin x4 Pad
(1) Thin x2 Pad

WORM-DIAL FIBAND OPERATION
LOOSEN HEAD-LOC SLIDERS
•With the helmet off, loosen all (4) Head-Loc Sliders by sliding
them away from the chincup.
CONNECT CHINSTRAP BUCKLE
•Place the helmet on your head and connect the low profile
chinstrap buckle. This is easiest when placing your index fingers
behind each side of the buckle as shown.
TIGHTEN FRONT STRAPS
•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.
ADJUST WORM DIAL
•Turn the Worm-Dial Adjustment to tighten the tband until it
is comfortably snug.
TIGHTEN BACK STRAPS
•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.
Head-Loc
Slider
7

H-NAPE CHINSTRAP OPERATION
LOOSEN HEAD-LOC SLIDERS
•With the helmet off, loosen all (4) Head-Loc Sliders by sliding
them away from the chincup.
CONNECT CHINSTRAP BUCKLE
•Place the helmet on your head and connect the low profile
chinstrap buckle. This is easiest when placing your index fingers
behind each side of the buckle as shown.
TIGHTEN FRONT STRAPS
•Tighten the front straps by pulling the Head-Loc Sliders toward your chin.
This is easiest when holding either side of the slider with your thumb and
middle finger while using your index finger in the top recess.
ADJUST NAPE PAD
•Position comfortably (as low as possible) on the back of your
head. Pull Head-Loc Slider with your right hand.
TIGHTEN BACK STRAPS
•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.
Head-Loc
Slider

9
NIGHT OPERATIONS AIRBORNE OPERATIONS
BREACHING / ATV
MISSION DOCUMENTATION
Bungee
IFF Strobe
Counterweight
Counterweight
NVGs
IR Illuminator O2 Mask
Goggles
COMMs Headset
COMMs Headset
Video
Camera Video
Camera
HMD Ballistic
Mandible
Side
Armor
Ballistic
Visor
There are three ways of attaching accessories to the FAST Helmet. The Ops-Core 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
VAS 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, 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

VAS SHROUD COMPATIBILITY
Helmet Compatability
Fits the standard MARSOC / WARCOM 3-hole NVG mount pattern
NVG & Mount Arm Compatability
The Ops-Core VAS Shroud is 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
VAS SHROUD
The VAS 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
Remove the center top pad, and position the top pads in the
helmet so there is enough space for the headband of the headset
to sit in between them.
Note: H-Nape users can disregard the remaining
instructions.
INSERT HEADSET HEADBAND
Flip the Fitband away from the front of the 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
Worm-Dial.
REATTACH FITBAND
Reattach the 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.
Reattach the Front 4 or 5 Row Pad.
COMMs HEADSET
TheLuxLinersystemiscompatiblewithavariety of COMMs headsets and hearing protection devices.
Instructions for use with headband style COMMs is below.
Impact Liner
Front of Fitband
DETACH FITBAND
Remove the 4 or 5 Row Front Pad from
the Fitband (the front row pad is held onto
the Fitband with small Velcro Tabs). Place
your index nger behind the front center of
the Fitband and carefully bend away from the
Impact Liner as shown. Pinch the Fitband and
use your thumb to slide the pad sideways ½”
towards the center of the helmet along the Impact
Liner. Repeat on both sides until the pad is released
from the key slots. Detach back of Fitband by simply
peeling it away from the Velcro Circles it is attached to.
Note: Do not pull the Front Fitband away from
the Impact Liner or you may break the 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 Worm-Dial Fitband Comfort Pads every 100 days or once/year.
•Replace Worm-Dial Fitband, or H-Nape Chinstrap, Hardware, and Lux Liner 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 Shroud and FAST Side Rails for signs of breakage.
•Visually check the Lux Liner’s Impact Liner for signs of breakage.
•Check that the Worm-Dial or H-Nape Chinstrap 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)
Lux Liner Kit
(Worm-Dial)
Lux Liner Kit
(H-Nape Chinstrap)
Front
EPP Pad
Worm-Dial Fitband
Chinstrap & Hardware
(or) H-Nape
Chinstrap & Hardware
Worm-Dial Fitband Comfort Pads
VAS
Shroud Kit
Bungees Kit
Repaint Helmet Shell
REPLACEMENT KITS
17

Nape
Comfort Pad
REPLACEMENT FITBAND COMFORT PADS
Right Side
Comfort Pad
Left Side
Comfort Pad
KIT INCLUDES THE FOLLOWING COMFORT PADS:
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
Left Side
Comfort Pad
Velcro Circles
Attach to Impact Liner
Right Side Comfort Pad
Note: H-Nape Chinstrap users can disregard this page.

ADDITIONAL PADS
(Also Included)
(1) Thin x2 Pad
(1) Thin x4 Pad
S/M M/L & L/XL
H-NAPE PADS WORM-DIAL PADS ADDITIONAL PADS
(Also Included)
(1) Thin x2 Pad
(1) Thin x4 Pad
S/M M/L & L/XL
REPLACEMENT CHINSTRAP & LUX LINER
REMOVE OLD WORM-DIAL FITBAND FROM LUX LINER
Place your index nger behind the front center of the Worm-Dial Fitband and carefully bend away
from the Impact Liner as shown. Pinch the Fitband and use your thumb to slide the pad sideways ½”
towards the center of the helmet along the Impact Liner. Repeat on both sides until the pad is released
from the key slots. Detach back of Fitband by simply peeling it away from the Velcro Circles it is
attached to.
Note: Do not pull the Front Fitband away from the Impact Liner or you may break the
Key Slots.
REMOVE LUX LINER PADS
Remove all Lux Liner Pads from the Lux Liner’s Impact Liner. Pads are attached to the Lux Liner by
Velcro Circles. Front row 4x or 5x pad for Worm-Dial version is held onto the Fitband by Velcro Circles
and Tabs. It can be easily removed by peeling away from the Impact Liner.
H-Nape Chinstrap version can be easily replaced by unscrewing hardware, removing old H-Nape
Chinstrap and installing new Chinstrap.
19
Insert the new Worm-Dial Fitband into the Key-Slots of the front Impact Liner by bending the Fitband
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. Then attach Lux Liner Pads.
Impact Liner
Front of Fitband
All Pads RemovedAll Pads Attached
LUX LINER REPLACEMENT PAD KIT INCLUDES THE FOLLOWING PADS:

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 70c using a hair dryer. Do not heat helmet
above 70c 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 Maritime
Kit A Kit B