David Clark HBT-61 Headset Parts Guide & Illustrated Catalog

David Clark HBT-61 Headset Parts Guide & Illustrated Catalog

Written by: Pilots HQ Staff

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Time to read 6 min

Keep your HBT-61 flying strong with our complete breakdown of features, parts, and upgrade options.

The David Clark HBT-61 is a Bluetooth listen-only headset tailored for industrial applications. Its defining feature is the ability to provide clear audio in high-noise environments without the need for a microphone, making it ideal for settings where communication is one-way. The headset's durable construction and comfortable fit ensure it can withstand the rigors of industrial use while maintaining audio clarity.


One of the standout features of the HBT-61 is its adjustable strap, which allows users to customize the fit for maximum comfort and stability. This is particularly important in dynamic environments where movement is frequent. Additionally, the headset's undercut gel earseals provide a snug fit that enhances noise isolation, ensuring that users can focus on the task at hand without distraction.


This guide will cover everything you need to know about the HBT-61, from its key features and specifications to maintenance tips and available upgrades. Whether you're looking to replace a worn-out part or enhance your headset's comfort, we've got you covered with detailed information sourced directly from the official David Clark IPC and cross-referenced against the Pilots HQ catalog.

The HBT-61 is a Bluetooth listen-only headset designed for industrial environments.

It features an adjustable strap (10370G-03) for a secure fit during use.

The headset includes undercut gel earseals (40863G-02) for enhanced comfort.

A charger cable (09923P-44) is included for convenient recharging.

The HBT-61 is ideal for high-noise environments, providing reliable audio clarity.

Why Pilots Love the HBT-61

  • Bluetooth connectivity allows for wireless audio streaming in industrial settings.
  • The adjustable strap (part number 10370G-03) ensures a secure and comfortable fit.
  • Undercut gel earseals (40863G-02) enhance comfort and noise isolation.
  • Includes a charger cable (09923P-44) for easy recharging.
  • Durable construction withstands the demands of industrial environments.
  • Listen-only design is ideal for one-way communication needs.
  • Lightweight design reduces fatigue during extended use.
  • Compatible with a range of Bluetooth-enabled devices for versatile use.

Specs at a Glance

  • Model Number: HBT-61
  • Part Number: 19549P-23
  • Weight: Not specified
  • Cord: Charger cable included
  • Design: Over-ear, listen-only

Noise Attenuation

The HBT-61 achieves noise attenuation through its over-ear design and high-quality ear seals. The undercut gel earseals (40863G-02) create a tight seal around the ear, effectively blocking out ambient noise. This passive noise reduction is crucial in industrial settings, where background noise can be a significant distraction.


Over time, the effectiveness of noise attenuation can degrade as the ear seals wear out. If you notice an increase in ambient noise, it may be time to replace the ear seals. The undercut gel earseals are a direct replacement and can be found as item 4 in the IPC, part number 40863G-02.

What's the difference between the David Clark HBT-61 and HBT-60?

The David Clark HBT-61 and HBT-60 are both Bluetooth listen-only headsets designed for industrial use, but they cater to slightly different needs. The HBT-61 includes an adjustable strap for a more customized fit, which can be particularly beneficial in environments where the headset needs to remain secure during movement. In contrast, the HBT-60 is designed with a fixed headband, offering a more straightforward design for users who prioritize simplicity over adjustability.


Both models share parts compatibility, including the undercut gel earseals (40863G-02), making maintenance and upgrades straightforward. However, the HBT-61's adjustable strap (10370G-03) is a unique feature not found on the HBT-60, providing an edge in terms of comfort and fit customization.


Parts Compatibility

  • Undercut Gel Earseal (pair) — 40863G-02
  • Adjustable Strap — 10370G-03

👉 For those who need a more secure fit, the HBT-61 is the better choice due to its adjustable strap.

Illustrated Parts Catalog

David Clark HBT-61 Parts Diagram
David Clark

HBT-61 Parts List

  1. Filter (Right) — 15512P-05
  2. Filter (Left) — 15512P-03
  3. Adjustable Strap — 10370G-03
  4. Undercut Gel Earseal (pair) — 40863G-02
  5. Nut & Washer Kit (10/pk) — 12052G-03
  6. Dust Cap — 13238P-28
  7. Charger Cable — 09923P-44

HBT-61 Item # 1 - 7

Comfort Upgrades Worth Considering for Your David Clark HBT-61

Looking to make your David Clark HBT-61 even more comfortable? These two upgrades are customer favorites:

Double-Foam Head Pad Kit (40688G-36):


The Double-Foam Head Pad Kit adds an extra layer of cushioning, making long listening sessions more comfortable. It's especially beneficial for users who wear the headset for extended periods in industrial environments.


👉 Consider this upgrade if you prioritize comfort during prolonged use.

Comfort-Gel Undercut Ear Seals (40863G-02):


These ear seals provide an excellent fit and enhance the passive noise reduction capabilities of the HBT-61. They are designed to contour to the shape of your ears, providing a more personalized and comfortable experience.


👉 Upgrade to these ear seals for improved noise isolation and comfort.

Maintenance Tips for Your HBT-61

  • Regularly inspect the adjustable strap (10370G-03) for signs of wear or damage.
  • Replace the undercut gel earseals (40863G-02) if they become cracked or lose their shape.
  • Ensure the charger cable (09923P-44) is free from frays or damage to maintain charging efficiency.
  • Clean the dust cap (13238P-28) regularly to prevent debris from entering the headset.
  • Store the headset in a cool, dry place to prolong the life of all components.

Proper maintenance will ensure your HBT-61 remains reliable and comfortable for years to come.

Adapters for the HBT-61

Accessories for the HBT-61

Genuine David Clark Parts, Fast Shipping

At Pilots HQ, we believe our job isn't finished when you buy a headset. We go further by offering:

  • Expert Education: Guides, blogs, and resources that explain how to care for and get the most from your David Clark HBT-61, including maintenance tips and parts breakdowns.
  • Maintenance Reminders: Helpful tips on when to replace ear seals, cords, and head pads to keep your HBT-61 comfortable, reliable, and ready for every flight.
  • Trusted Inventory: Only genuine David Clark headsets, adapters, and replacement parts — no imitations.
  • Fast, Reliable Shipping: Get what you need quickly, so your flying isn't delayed by missing parts.
  • Pilot-Focused Service: Our team understands aviation and is here to help you choose the right headset, adapter, or replacement component for your aircraft and mission.

👉 With Pilots HQ, you're not just buying products — you're investing in long-term comfort, clear communication, and confidence every time you fly.

David Clark Company Logo
David Clark Company

How do I replace the ear seals on my HBT-61?

To replace the ear seals, remove the old ones and attach the new undercut gel earseals (40863G-02) by pressing them firmly into place.

What should I do if my HBT-61 isn't charging?

Check the charger cable (09923P-44) for any damage. Ensure it is properly connected to a power source and the headset.

Can I use the HBT-61 in a high-noise environment?

Yes, the HBT-61 is designed for high-noise environments, providing excellent passive noise reduction with its gel earseals.

Is the adjustable strap replaceable?

Yes, the adjustable strap (10370G-03) can be replaced if it becomes worn or damaged.

How often should I replace the ear seals?

Replace the ear seals when they show signs of wear or if noise isolation decreases, typically every 6-12 months depending on use.

What is the most common issue with the HBT-61?

The most common issue is reduced noise isolation due to worn ear seals. Replacing them with part number 40863G-02 can resolve this.

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Pilots HQ LLC.

Pilots HQ Staff

At Pilots HQ, we’re more than just a store — we’re a crew of aviation enthusiasts and support staff dedicated to helping pilots and professionals get the gear and service they need. Our team shares insights, tips, and stories to keep you flying with confidence.