Bullard RS4RP Four-Point Ratchet Suspension Replacement Manual

1. Product Overview

The Bullard RS4RP Four-Point Ratchet Suspension is a replacement component designed to maintain the safety and comfort of your Bullard hard hat. This suspension system is crucial for impact absorption and ensuring a secure fit. Regular replacement of the suspension is recommended to ensure optimal protection.

• Secure Fit: Designed to fit snugly, preventing the hard hat from dislodging during use.
• Easy Adjustment: Features a FlexGear ratchet system for quick and precise sizing adjustments, even with gloved hands.
• Enhanced Comfort: Includes a polyester brow pad for improved comfort during extended wear.
• Critical Safety Component: The suspension is integral to the hard hat's impact protection system.

Figure 1: The Bullard RS4RP Four-Point Ratchet Suspension, shown inside a hard hat. This image illustrates the complete suspension system, including the webbing and ratchet mechanism, designed for secure head protection.

2. Package Contents

The Bullard RS4RP package contains the following item:

• One (1) Bullard RS4RP Replacement Four-Point Ratchet Suspension with Polyester Brow Pad.

3. Compatibility

This replacement suspension is specifically designed for use with the following Bullard hard hat models:

• Bullard S51 Hard Hats
• Bullard S61 Hard Hats
• Bullard S62 Hard Hats
• Bullard S71 Hard Hats
• Bullard AboveView Hard Hats
• Bullard AboveView Elevate Hard Hats

Ensure your hard hat model is listed above for proper fit and safety.

4. Safety Information

The suspension system is a vital component of your hard hat's protective capabilities. Adhere to the following safety guidelines:

• Regular Replacement: It is recommended to replace the hard hat suspension at least once every year, or more frequently if exposed to harsh conditions or heavy use.
• Immediate Replacement: If the suspension shows any signs of damage, wear, cracks, or deformation, replace it immediately. Do not attempt to repair damaged components.
• Shell Inspection: Always inspect the hard hat shell for damage (dents, cracks, penetration) when replacing the suspension. If the shell is damaged, replace the entire hard hat.
• Use Genuine Parts: Only use genuine Bullard replacement parts to ensure compatibility and maintain safety standards.

5. Setup and Installation

Follow these steps to properly install the Bullard RS4RP replacement suspension into your compatible hard hat:

1. Remove Old Suspension: Carefully detach the old suspension from the hard hat shell. Most Bullard hard hats feature attachment points (slots or clips) that allow the suspension to be removed by gently pressing or twisting. Note how the old suspension was oriented for correct installation of the new one.
2. Inspect Hard Hat Shell: Before installing the new suspension, thoroughly inspect the hard hat shell for any signs of damage, such as cracks, dents, or discoloration. If any damage is found, the entire hard hat should be replaced.
3. Orient New Suspension: Identify the front of the new suspension (typically indicated by the brow pad or ratchet mechanism). Align it with the front of the hard hat shell.
4. Attach Suspension: Insert the suspension's attachment tabs or clips into the corresponding slots or holes inside the hard hat shell. Ensure all four attachment points are securely fastened. You should hear a click or feel a firm connection for each point.
5. Verify Security: Gently pull on the installed suspension to confirm it is firmly seated and cannot be easily dislodged.

Figure 2: A detailed view of the suspension system's attachment points and ratchet mechanism within a hard hat. This image helps visualize how the suspension connects to the hard hat shell.

6. Operating and Adjustment

The Bullard RS4RP suspension features a FlexGear ratchet for easy and precise fit adjustment.

1. Initial Fit: Place the hard hat on your head. The suspension should feel snug but not uncomfortably tight.
2. Adjusting the Ratchet: Locate the large knob at the back of the suspension (the FlexGear ratchet). Turn the knob clockwise to tighten the suspension for a more secure fit, and counter-clockwise to loosen it. Adjust until the hard hat is stable on your head and does not wobble or slip, even when bending over.
3. Vertical Height Adjustment: The suspension offers vertical height adjustments (two in the front, three in the rear) to customize the depth of the hard hat on your head. To adjust, carefully detach the suspension webbing from its current slot and re-insert it into a higher or lower slot as desired. Ensure all corresponding points are adjusted evenly.
4. Brow Pad Comfort: The polyester brow pad should rest comfortably against your forehead. If it feels uncomfortable or misaligned, re-check the suspension's vertical height and overall fit.

Figure 3: Diagram highlighting the features of the Bullard ratchet suspension, including the 6-point Flex-Gear suspension, flex points, nape cushion, large ratchet knob, absorbent cotton brow pad, and vertical height adjustments.

7. Maintenance

Proper maintenance extends the life and effectiveness of your suspension.

• Cleaning: Clean the suspension with mild soap and water. Rinse thoroughly and allow to air dry completely before re-installation or storage. Avoid harsh chemicals or solvents, as these can degrade materials.
• Inspection: Regularly inspect the webbing, plastic components, and brow pad for signs of wear, fraying, cracks, or damage. Pay close attention to the ratchet mechanism to ensure it operates smoothly and locks securely.
• Brow Pad Replacement: The polyester brow pad is removable and replaceable. If it becomes soiled, worn, or loses its cushioning, replace it with a genuine Bullard replacement brow pad.
• Storage: Store the hard hat and suspension in a cool, dry place away from direct sunlight, extreme temperatures, and chemicals.

8. Troubleshooting

If you encounter issues with your Bullard RS4RP suspension, consider the following:

• Hard Hat Feels Loose:
  • Ensure the ratchet knob is tightened sufficiently.
  • Check if the suspension is correctly seated in all attachment points within the hard hat shell.
  • Verify that the hard hat model is compatible with the RS4RP suspension.
• Hard Hat Feels Uncomfortable:
  • Adjust the vertical height settings of the suspension for a better fit.
  • Ensure the brow pad is positioned correctly and is not worn out.
  • Loosen the ratchet slightly if it feels too tight.
• Ratchet Mechanism Not Working:
  • Inspect the ratchet for any visible damage or debris.
  • If the ratchet is damaged or not functioning correctly, the entire suspension must be replaced.
• Suspension Detaches Easily:
  • Re-check all attachment points to ensure they are fully engaged with the hard hat shell.
  • Inspect the suspension's attachment tabs and the hard hat's slots for wear or damage. If damaged, replace the affected component.

For persistent issues or concerns, contact Bullard customer support.

9. Specifications

10. Warranty and Support

For specific warranty information regarding your Bullard RS4RP Four-Point Ratchet Suspension, please refer to the documentation provided with your original hard hat or visit the official Bullard website. For technical support, replacement parts, or any inquiries, please contact Bullard customer service directly.

You can find more information and contact details on the Bullard Store on Amazon or the official Bullard website.