Maintenance Status Traffic Light Checklist

The maintenance status traffic light checklist is a tool to gauge the severity of issues found during an inspection. The maintenance schedule is to ensure that the helmet is still providing the four key functions to the aviator or helmet user.
1. Impact attenuation. 2. Noise attenuation. 3. Eye protection. 4. Communication.
Green: Within manufacturer specifications, no repair or action needed.
Yellow: Will still provide the function intended, but needs service to operate at full efficacy. Action: Repair at next Annual Inspection or Refurbishment
Red: Not in a serviceable condition. Action: Recommended not to fly with helmet until condition is addressed and reinspected.

HELMET AND RETENTION COMPONENTS

Component Name (Reference Number)	Green	Yellow	Red	Inspect For
SHELL (1)
				Soft spots in shell
				Paint chips reveal fibers
				Cracked or broken fibers
				Delamination of shell
				10 year lifespan
				Hairline paint cracks
SHOCK LINER (2)
				Any crack
				Debris on liner
				Minor leading edge damage, within 1/2” of the edge of the shock liner
				Annual inspection overdue
				Velcro on front leading edge missing, but trim lock is intact
				Fewer than three velcro pads securing the comfort liner
				Any compression more than 1/2” from edges of shock liner
NEPHOS™ COMFORT LINER (3)
				Deformed
				Soiled and debris
				Torn
Kairos™ RETENTION ASSEMBLY (4)
				Stitching loose, worn, or missing
				Soiled and debris
				Discolored
NAPE AND DIAL ASSEMBLY (5)
				Broken or missing
				The dial is not functioning properly
				Cracks or holes are present on the nape
NAPE PAD (6)
				Missing
				Dirty
				Torn
CAM LOCKS AND STRAPS (7)
				Cam lock missing
				Cam lock cracked
				Cam lock does not function
				Cut straps
				Frayed Straps
CHIN STRAP (8)
				Cut or damaged stitching
				Frayed
				Not attached or properly fitted
				Discolored
CHIN PAD (9)
				Not attached
				Torn
MAGNETIC BUCKLE CLASP (10)
				Components are missing
LADDER LOCK (11)
				Component is missing or cracked
TRIM LOCK (12)
				Separating from shell
				Missing
				Torn

VISOR COMPONENTS

Component Name (Reference Number)	Green	Yellow	Red	Inspect For
VISOR COVER ASSEMBLY (13)
				Paint chips
				Is loose or missing hardware
				NVG quick release non-functional *Night operations
				Cracks not interfering with visor function
INNER VISOR LENSES (14)
				Missing actuator
				Actuator spring knob does not work
				Actuator pin missing
				Actuator does not move freely in track
				Cracks or crazing in the area of view
OUTER VISOR LENSES (15)
				Cracks or crazing in the area of view
VISOR LOCK (16)
				Non-operable or missing
				Missing left-hand screw or other components

COMMUNICATION COMPONENTS

Component Name (Reference Number)	Green	Yellow	Red	Inspect For
COMMUNICATION CORD (17)
				Intermittent or no signal
				Corrosion or pitting of plug
				Frayed cord braiding
				Exposed wires
				Inappropriate plug for airframe
MICROPHONE BOOM SUPPORT ASSEMBLY (18)
				Missing components
				Does not support microphone boom or spins freely
MICROPHONE BOOM (19)
				Damaged or does not support microphone
MICROPHONE CORD (20)
				Frayed or damaged cord (cuts)
				Corrosion or pitting of plug
				Intermittent or no signal
MICROPHONE (21)
				Intermittent or no signal
				Missing microphone muff
EARPHONES (SPEAKERS) (22)
				Intermittent or no signal
EAR CUPS (23)
				Cracks or holes are present
EAR SEALS (24)
				Missing
				Dirty
				Not adhered to ear cup
				Torn or cut

ACCESSORIES

Component Name (Reference Number)	Green	Yellow	Red	Inspect For
VOLUME CONTROL (25)
				Intermittent or no signal
				Missing knob
BATTERY PACK HOLDER (26)
				Missing
				Missing *If using night vision goggles
				Torn
				Torn *If using night vision goggles