Osprey Mk 4

Body Armour

USER CARE AND

ASSEMBLY INSTRUCTIONS
Osprey Mk 4 Body Armour

Body Armour Cover- Vest Front- x1 Body Armour Cover- Vest Back- x1

Waistbands Set - x1

OPS Panel & T Bar fittings - x1

Shoulder Guards, Pair

Left & Right with
elasticated fittings - x1

Cummerbunds, Pair Left & Right - x1 Brassards, Pair

Left & Right with
elasticated
fittings - x1

2 Piece Full Collar - x1

Blanking Panels,
Ancillaries Set - x1 2 Piece Half Collar - x1 Pair - x1

2
 Accessories & Parts Listing

Pair Small Armour

Front Armour Back Armour Plates - x1
Plate - x1 Plate - x1

First Aid Commanders

Pouch Pouch
Front Plate Cover - x1 Back Plate Cover - x1 x1 x1

Water LMG 100 UGL 8 Utility

Bottle Pouch Round Pouch Round Pouch Pouch
x1 x1 x1 x1

SA80 2 Mag SA80 Single Mag SA80 Single Mag Sharpshooter 9mm Pistol AP Grenade Smoke Grenade
Ammo Pouch Ammo Pouch Ammo Pouch 3 Mag Ammo Pouch Ammo Pouch Pouch Pouch
x4 x3 x3 x1 x2 x2 x2

NB: A set of Soft Armour is also included but has not been illustrated. 3
Light Fighting Order

Non Slip NB: When no collar is fitted

Shoulders to the vest, the collar tabs
are tucked under the
main vest shoulder join.

Grab
Handles

OPS Panel with

adjustable
T Bar fittings

T Bar
Adjustment

Complete Fighting Order

Full Collar
Showing Full Collar,
Brassards, Shoulder
Guards
Cummerbunds
& Shoulder Guards

Brassards

Brassards

The OPS Panel

is removed. Replaced Half Collar
with Cummerbunds
fitted with
adjustable front
webbing straps

4
Assembly

Hard Armour Plates One way

Studs
The studs used throughout
the items in the Osprey Mk4
Body Armour, use One Way
Studs these prevent
accidental release of
fastenings whilst in use.
They require no special
equipment or tools to open.
Any use of tools could
Front and Back Hard Armour Plates should only be used in the fitted permanently damage the
covers provided. These use simple flap & touch & close fastenings. fixings.
NB: Armour plates should be regularly inspected see page 15.
The stud is designed to only
fasten or release when
Fitting Hard Armour pushed or pulled in one
direction, this direction is
indicated by a dot on the
Open the inner stud button.
pocket inside the
front face of the vest The top stud
features
a locking nub
on the top
of the
inner rim

To Close
2 Insert the Hard Armour,
1
Ensuring that the front faces
away from the body. 2

3 Pull from
Dot to Open
To close the stud the locking
nub at the top of the female
stud should be looped onto the
Close the pocket securely. raised rim of the male.
Push the base of the stud and
the two units lock.
To Open, simply pull the stud
Armour for both the back and from the base.
the front of the vest is fitted
in the same manner.
5
Assembly

Using the Small Armour Plate

As an alternative to the larger Hard
Armour Plates,
the Small Armour Plates may also
be fitted into the vest Front & Back.

The pocket is located inside the main

plate pocket and is fitted in the same way.

Fitting the Soft Armour

1
This is best fitted after the Hard Armour
has been installed.

Install the armour into the vest recess, ensuring

it lies flat and that the labels face the body.

Pull each tab through the shoulder openings.

The top of the shoulder opening features a small

pocket, insert the tab into this pocket.

Close the small pocket.

The tabs will be held in place

by the hook & loop fixings. 3

6
Assembly

Assembling the Main Vest Body

On a suitable flat area.
Lay out both parts of the Vest as indicated
1

Connect the Front & Back Vest panels

together at the shoulders using the
Hook & Loop and the two stud fixings.

2
3

To complete the vest assembly bring the extended

sides of the back panel around to fix to the front panel,
fasten these at the sides by hook & loop fabric.

The waist band ( pre fitted) is adjustable.

7
Assembly

Fitting the OPS Panel

2 3

The studded loops

hold the OPS Panel to 4
the main vest body
T Bars & Webbing
straps add fixing
points to the sides.

The Webbing can

be adjusted for
fitting & comfort.
First Fixing of the OPS Panel is by Hook & Loop

Installing Hard Armour Plates

into the Cummerbunds

The Cummerbunds include pockets to

hold the small Armour Plates, adding
additional protection to the lower
torso. Access to the pocket, is by
a simple flap sealed by
Hook & Loop fastenings.

8
Assembly

Fitting the Cummerbunds

The Moll bars on the reverse of

the Cummerbund should be
threaded through the Moll webbings
on the vest. See page 11 for further
details on using the Moll system.

The Blanking Panels

are used to prevent
the hook & loop
fixing during the
assembly process.

The Cummerbunds
can be adjusted
using the front straps.

Fitting the Collars Join the two collar sections,

and fit the collar to the Vest
A choice of collars may be fitted. Collar Flaps using the Hook
The full collar or the Half Collar. 1 & Loop fixings and complete
buy closing the three studs
Both Collars are supplied as a on each side.
two piece unit and fit similarly.

At the back of the collar,

2
pull the webbing strap through
the central top loop on the
Vest Moll Webbing

Full Collar

3
Close the stud on the webbing
strap to complete fitting.

The front of the collar is

adjustable for comfort.
Half Collar
9
Assembly

Fitting the Brassards & Shoulder Guards

The Brassards & Shoulder Guards offer integrated
protection for the upper arm and shoulder.
Properly fitted they will not impede movement
& flexibility.

To fix the Brassard to the Vest, Open the main

shoulder fixing and attached the top tab to the
exposed vest using the Hook & Loop fixings.
Reattach the shoulder fixing.

The Shoulder Guards

attach to the vest body
using hook and loop
fixings & 3 studs.
Additional stability
& flexibility is provided
by attaching the
studded elasticated
strap to the Brassard.

The Brassards are additionally fixed to the vest

by two short elasticated studded straps.
The first attaches to the top front shoulder, as
seen above.
The second is attached through the shoulder
fixing to its fixing point on the back, see the
photograph right.

10
Using the Moll fixing system

The pouches and accessories provided for the

Osprey Mk4, make use of the Moll fixing
system. Properly fitted, this provides an
extremely strong bond between the pouch or
other accessory and the Vest itself.

The Rigid Moll Bar of the Pouch, should be woven

through each of the horizontal webbings in turn.

The vest panels

feature horizontal
Moll webbings

Moll Webbing
on the Vest

Pouches and
Accessories carry
horizontal Moll
webbings and a
rigid Moll bar.
The base of each
bar features a one
way stud to lock
the bar to the body
of the pouch.

11
Fitting the Ancillary items

Drop Sling Attachment Hydration Unit

Fixings.
The Drop sling is secured to the rear of the vest,
using a T Bar fed into a rear Moll Fixings are provided to meet the
requirements of most Hydration
Firstly detach the T Bar and D ring from the sling assembly units. These can be positioned
and feed this through the Moll webbing. onto the Vest using the integral
Moll webbings.
Reattach the sling ready for use.

2 x Side release buckles

mounted on a T Bar provide
attachments for the top of the
hydration unit.

An additional T Bar with

2 x Side release buckles with
adjustable webbing straps
provide attachments for the
base of the hydration unit.

Further support is provided

by 6 x short studded webbing
fixings.

12
Rank Strap

The Rank strap can be is fitted onto the

front of the vest.
It should be threaded through three
Moll webbings.

13
Hard Armour Plate Inspection

These checks should be undertaken at regular intervals to

ensure that the plates still provide full protection.

1 Carefully remove the

Armour Plate from
the cover.

2 Run your hand over

the front of the Plate
feeling for debris
and/or damage.
Front Plate Back Plate
3 Visually check the
outer green fabric for
rips and tears.

4 Visually check the

faces of the Plate for
cracks or damage.

Cracks will be
highlighted by a
definite white line.

Impacts will be visible

as a white indentation
and radiating
fractures. See the
illustration opposite.

5 Damaged or Cracked
Plates MUST be
replaced.

6 Minor blemishes or
air pockets do not
pose any risk.

14
 Soft Armour Maintenance NATO Stock
Numbers (NSNs)

Inspection for panels and covers should follow the same

guidelines as during laundering.

It is essential that the following regular maintenance is

conducted:
Cover Osprey Body
As a minimum period. The body armour is to be
Armour Mk4
inspected annually by the QM Department.
Size 170/100
8470-99-925-0872
The body armour should be inspected for signs of
damage to armour panels and protective covers. Cover Osprey Body
Armour Mk4
Armour panels should also be inspected at the Size 170/112
earliest convenient time if the armour has had any 8470-99-925-0873
physical contact with objects likely to cause damage. Cover Osprey Body
Armour Mk4
The outer cover is to be cleaned in a washing Size 180/104
machine, in accordance with the manufacturers 8470-99-925-0874
instructions. Cover Osprey Body
Armour Mk4
Fillers are to be removed prior to laundering. Size 180/116
8470-99-925-0875
Cover Osprey Body
Photography, Design & Production - Corvus Design Services. 01271 374593

Cleaning Armour Mk4

Size 190/108
8470-99-925-0876
THE COVER AND FILLER MUST BE SEPARATED IN Cover Osprey Body
ACCORDANCE WITH THE FITTING INSTRUCTIONS BEFORE Armour Mk4
CLEANING Size 190/120
8470-99-925-0877
Cover The cover is washed in accordance with
the manufacturers instructions. Cover Osprey Body
Armour Mk4
Filler To clean the filler, wipe the surface of the Size 200/116
8470-99-925-0878
protective cover using a damp cloth.
Cover Osprey Body
DO NOT IMMERSE IN WATER Armour Mk4
Size 200/124
Dry thoroughly before inserting back into 8470-99-925-0879
the cover.

15
 JOINT SUPPORT CHAIN

DE & S
Joint Support Chain
Personal Combat Equipment
Integrated Capability Group
Spur 6
Beckford Block
Ensleigh
Bath
BA1 5AB

Product Design & Development

Booklet Production & Photography

CQC Limited, Barnstaple Devon.

www.cqc.co.uk