Aqua Lung G3000SS Operation & Maintenance Manual
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Aqua Lung G3000SS Operation & Maintenance Manual

Aqua Lung G3000SS Operation & Maintenance Manual

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AQUA LUNG G3000SS HELMET
OPERATIONS & MAINTENANCE MANUAL
Rev. 5/18

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  • Page 1 AQUA LUNG G3000SS HELMET OPERATIONS & MAINTENANCE MANUAL Rev. 5/18...
  • Page 2 Aqua Lung America, Inc. It may not be distributed through the internet or computer bulletin board systems without prior consent in writing from Aqua Lung America.

  • Page 3: Table Of Contents

    IV. USER CHECKLISTS ..............................13 CHECKLIST 1: G3000SS Diving Helmet Daily Checklist ..................14 CHECKLIST 2: G3000SS Diving Helmet Pre-Dive Checklist ..................18 CHECKLIST 3: G3000SS Diving Helmet In-Water Checklist for Supervisor ............21 CHECKLIST 4: G3000SS Diving Helmet Post-Dive Checklist ..................23 TECHNICAL SECTION V.
  • Page 4 Neck Retainer and Locking System ........................47 Neck Dam and Quad Ring .............................47 VII. TECHNICIAN CHECKLISTS ............................48 CHECKLIST 5: G3000SS Diving Helmet Monthly Inspection and Maintenance Checklist ........49 CHECKLIST 6: G3000SS Diving Helmet Annual Inspection and Maintenance Checklist ........54 Part 1 - Helmet Disassembly ..........................55 Part 2 - Helmet Reassembly ..........................62...
  • Page 5 Q. Cleaning and Lubricating ............................93 R. Annual Service Kit ..............................94 S. Field Spares Kit ............................... 95 T. Maintenance Log Sheet ............................96 IX. G3000SS DIVING HELMET SPARE PARTS LIST ......................97 X. G3000SS DIVING HELMET ACCESSORIES ....................... 100...

  • Page 6: Safety Information

    The product has been modified without consent of Aqua Lung America, Inc. • The product has been misused, damaged, put into a situation or service for which the product is not intended or if the product has not been correctly maintained according to the G3000SS Diving Helmet Operations & Maintenance Manual.

  • Page 7: Operations Section

    (Annex II) of the directive. The DNV GL Certificate Nos are 55594-14 HH, and 55594-14 HH Addition 1. The CE certification for the G3000SS Diving Helmet includes the use of the Bailout Switch Block and the Helmet Side Block. See Bailout Configuration section below for further information.

  • Page 8: Dive System Requirements

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual DIVE SYSTEM REQUIREMENTS The G3000SS Diving Helmet is used with the following minimum equipment: • Surface gas control system (panel) providing a regulated surface supply. • Diver’s umbilical, including gas hose and voice communications cable.

  • Page 9: Bailout Configurations

    BAILOUT CONFIGURATIONS All Emergency Gas Supply (EGS) or bailout supply configurations use a diving cylinder and first stage regulator fitted with a submersible pressure gauge (SPG) and an adjustable pressure relief valve (AP0849/K). WARNING: The EGS/Bailout supply first stage regulator must be fitted with a pressure relief valve in a Medium Pressure (MP) port.
  • Page 10 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual Bailout Configuration 1 EGS / Bailout Cylinder with Harness-Mounted Switch Block Upper hose routed from harness-mounted Lower hose routed from EGS / bailout cylinder switch block to helmet manifold. to harness-mounted switch block.

  • Page 11: Helmet Set-Up Procedures

    Regulated surface supply pressures for the G3000SS diving helmet are detailed in the In-Water Checklist. Gas systems used to supply the G3000SS helmet must be capable of supplying gas to the diver at the required supply pressure and flow rates. The use of unregulated gas sources is extremely dangerous.

  • Page 12: Use With Low Pressure Oxygen

    RMV. HELMET WEIGHT AND MASS The weight of the G3000SS diving helmet is 31.5 lb (14.3 kg). This equates to a mass of 140 Newtons. HEAD PROTECTION The G3000SS diving helmet provides Class B head protection as detailed in EN 15333-1: 2008.

  • Page 13: Iv. User Checklists

    Checklist 2 G3000SS Diving Helmet Pre-Dive Checklist Checklist 3 G3000SS Diving Helmet In-Water Checklist for Supervisor Checklist 4 G3000SS Diving Helmet Post-Dive Checklist NOTE: The terms “hook”, “loop” and “hook & loop” are used throughout this manual. Hook & Loop is commonly known as Velcro®, which is a trademarked brand of hook &...

  • Page 14: Checklist 1: G3000Ss Diving Helmet Daily Checklist

    G3000SS DIVING HELMET DAILY CHECKLIST BEFORE DIVING THE G3000SS DIVING HELMET, THE PROCEDURES IN THIS CHECKLIST MUST BE COMPLETED, NORMALLY ON A DAILY BASIS (I.E. PRIOR TO THE FIRST DIVE OF THE DAY). NOTE: The procedures in this checklist are to be performed only by personnel who have received appropriate training in the operation of the G3000SS diving helmet.
  • Page 15 DAILY CHECKLIST (continued) ACTION PROCEDURE INITIALS NECK RETAINER AND • Visually inspect the neck retainer assembly for signs of damage, such as bends. Confirm that LOCKING SYSTEM the retainer fits properly. (must be completed by diver/tender) • Make sure the locking system (both L and R) is properly working and not deformed in any way.
  • Page 16 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual DAILY CHECKLIST (continued) ACTION PROCEDURE INITIALS EGS INSPECTION • Visually inspect all EGS hoses for any signs of damage or defect. (must be completed by diver/tender) • Ensure that the bailout cylinder is within the VIP and the hydrostatic date.
  • Page 17 DAILY CHECKLIST (continued) ACTION PROCEDURE INITIALS ATTACH THE UMBILICAL • Confirm the check valve is properly functioning by orally checking it (suck on valve to confirm seal). (to be completed by tender) • Blow air through the umbilical to remove any debris, and attach the umbilical into the umbilical adapter located on the check valve.

  • Page 18: Checklist 2 G3000Ss Diving Helmet Pre-Dive Checklist

    NOTE: The procedures in this checklist are to be performed only by personnel who have received appropriate training in the operation of the G3000SS diving helmet. NOTE: Aqua Lung strongly recommends that the diver be assisted by the tender or supervisor when preparing for diving and conducting the procedures in this checklist.
  • Page 19 PRE-DIVE CHECKLIST (continued) ACTION PROCEDURE INITIALS SUPPLY GAS • Supervisor must ensure the diver has sufficient breathing gas pressure supplied to the helmet (must be completed by supervisor) for depth. BREATHING SYSTEM • Ensure proper functioning of free flow valve by opening and closing the valve.
  • Page 20 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual PRE-DIVE CHECKLIST (continued) ACTION PROCEDURE INITIALS CHECK DIVER'S ENTIRE • Check adjustment and fit of the entire rig, specific points: (must be completed by supervisor) • Head liner secured inside the helmet shell.

  • Page 21: Checklist 3: G3000Ss Diving Helmet In-Water Checklist For Supervisor

    CHECKLIST 3 G3000SS DIVING HELMET IN-WATER CHECKLIST FOR SUPERVISOR WHEN DIVING THE G3000SS DIVING HELMET, THE PROCEDURES IN THIS CHECKLIST MUST BE COMPLETED. WARNING: Aqua Lung strongly recommends completion of this checklist and meeting the minimum requirements provided before using the G3000SS diving helmet.
  • Page 22 HP Gas Supply Systems: The G3000SS Diving Helmet Regulated Supply Pressure Table applies to conventional surface supply systems providing a regulated gas supply to the diver through an MP umbilical. If a high pressure (HP) gas supply system is used, the information in the regulated supply pressure table does not apply.

  • Page 23: Checklist 4 G3000Ss Diving Helmet Post-Dive Checklist

    USING THE G3000SS DIVING HELMET. NOTE: The procedures in this checklist are to be performed only by personnel who have received appropriate training in the operation of the G3000SS diving helmet. WARNING: Aqua Lung strongly recommends completion of this checklist and meeting the minimum requirements provided before using the G3000SS diving helmet.
  • Page 24 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual POST-DIVE CHECKLIST (continued) PROCEDURE INITIALS 1. Secure and bleed down the breathing gas supply and the EGS hose. 2. Disconnect all helmet gas connections and disconnect the communication wires / cable. Replace hose caps onto hose adapters after removing all water from the hose adapter.
  • Page 25 POST-DIVE CHECKLIST (continued) PROCEDURE INITIALS 8. Remove the microphone from the oral-nasal mask. Wash the oral-nasal mask with soap and water, rinse with fresh water and allow to dry. 9. If required, clean the inside of the helmet with soap and water, rinse with fresh water and allow to dry.

  • Page 26: Technical Section

    It is strongly recommended that all repairs are completed in accordance with this manual. If you do not completely understand all of the procedures outlined in this manual, contact Aqua Lung to speak directly with a technical advisor before proceeding any further.

  • Page 27: Technician Checklists

    5. Use only genuine Aqua Lung parts provided in the service kits. DO NOT attempt to substitute any part with another manufacturer's, regardless of any similarity in shape or size. Substitution with other manufacturer's parts constitutes an after-market modification of the product and renders all warranties null and void.

  • Page 28: Step-By-Step Disassembly / Assembly Instructions

    VI. STEP-BY-STEP DISASSEMBLY / REASSEMBLY PROCEDURES The technical procedures in this section are to be performed only by personnel who have received factory authorized training through an Aqua Lung Service and Repair Seminar. NOTES ON DISASSEMBLY AND REASSEMBLY All components must be clean and fully serviceable prior to assembly.

  • Page 29: G3000Ss Diving Helmet Disassembly Procedures

    G3000SS DIVING HELMET DISASSEMBLY PROCEDURES NECK DAM AND QUAD RING 1. Remove neck dam assembly from 2. Inspect chin strap (76) for damage 3. Remove the quad ring (68) from the helmet shell (1). Inspect the and replace as required. Inspect both...

  • Page 30: Head Liner

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual NECK RETAINER AND LOCKING SYSTEM (continued) 9. Remove the latch spring (8) from 7. Latch catch assemblies removed 8. Use a 1/4" allen / hex key to remove from helmet. button cap screw (10) and latch spring the latch (2 or 3).

  • Page 31: Nose Clearing Device (Ncd)

    NOSE CLEARING DEVICE (NCD) 14. Unscrew the knob (67) from the 16. Remove both o-rings (66) from 15. Remove NCD (65) from the helmet shaft of the nose clearing device (65). shell (1). Inspect NCD for damage. the NCD. Inspect nose pad (64) for damage, replace if required.

  • Page 32: Communications

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual COMMUNICATIONS 20. Remove both (L & R) speakers 21. Remove and visually inspect 22. Remove the comms terminal block (30 & 40) and microphone (32) by the speakers (30 & 40), microphone...

  • Page 33: Double Exhaust / Water Dump Valve

    DOUBLE EXHAUST / WATER DUMP VALVE 29. Use a 5/8" low profile wrench to hold 30. Unscrew nut (20c) from the valve 31. Remove the nut (20c), spring the swagelock connector (33) in place. stem (60) using a 3/8" flat blade (20b) and handwheel knob (20a) Apply a 11/16"...

  • Page 34: Manifold

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual MANIFOLD 37. Using a 3/16" allen / hex key, 38. Remove the manifold body (48) 39. Remove the manifold gasket (45) remove both the long (41) and from the helmet shell (1).

  • Page 35: Airway

    REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL. The above named manual forms part of the formal support documentation for the G3000SS Diving Helmet. It is to be read, and the instructions applied as directed, in conjunction with this manual.

  • Page 36: Defogger

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual DEFOGGER 55. Remove the defogger train (38) 56. Remove the free flow barrel (34) 57. The helmet defogger system from the free flow barrel (34). from the free flow / water dump valve.
  • Page 37 FREE FLOW / WATER DUMP VALVE (continued) 64. Place the valve stem (60) onto 65. Using the valve stem (60) unscrew 66. Using reversible circlip pliers, the valve seat (58). the valve seat (58) from the valve remove the valve snap ring (57) body (55).

  • Page 38: Face Port

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual FACE PORT 70. Using a #3 Phillips screwdriver, 71. Remove the retainer port (12) 72. Separate the face port (13) from remove the screws (11) from the from the face port (13).

  • Page 39: G3000Ss Diving Helmet Reassembly Procedures

    G3000SS DIVING HELMET REASSEMBLY PROCEDURES FACE PORT 1. Use a clean cloth to wipe any 2. Place the face port (13) into the 3. Place the port retainer (12) over the particles or debris off the o-ring helmet shell (1).

  • Page 40: Free Flow / Water Dump Valve

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual FREE FLOW / WATER DUMP VALVE Center Ridge 6. Install both o-rings (54 & 56) onto 7. Install the exhaust valve (18) onto 8. Using reversible circlip pliers, install the valve body (55).

  • Page 41: Airway

    FREE FLOW / WATER DUMP VALVE (continued) Notch 16. Temporarily install the exhaust 15. Install the free flow / water dump valve cover (19), three spacer rings valve into the helmet shell (1). Align (17) and three screws (11) onto ex- the swagelock connector opening with haust port.

  • Page 42: Double Exhaust / Water Dump Valve

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual MANIFOLD (continued) 23. Wrap both check valves (50), SCUBA 24. Thread the hose fitting assembly into 25. Install both o-rings (44) onto (52) and hose fitting (51) with two rounds the right and SCUBA fitting assembly the manifold insert (43).
  • Page 43 DOUBLE EXHAUST / WATER DUMP VALVE (continued) Center Ridge 32. Install the dual exhaust bushing 33. Place the dual exhaust seat (16) 34. Install the exhaust valve (18) onto (15) over the valve bonnet (63). over the dual exhaust bushing (15). the dual exhaust seat (16).

  • Page 44: Defogger

    REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL. The above named manual forms part of the formal support documentation for the G3000SS Diving Helmet. It is to be read, and the instructions applied as directed, in conjunction with this manual.

  • Page 45: Oral - Nasal Mask

    ORAL - NASAL MASK 48. Insert the inhalation valve stem 49. Install the inhalation valve housing 50. Install the microphone (32) into (36) into the center hole of the inha- (37) into the left side of the oral nasal the right side of the oral nasal mask lation valve housing (37).

  • Page 46: Head Liner

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual COMMUNICATIONS (continued) 57. Use a 15/16" deep socket and 58. Screw the SS blank plug onto the 59. Install new plastic tubing (85) foot pound torque wrench to tighten comms bulkhead (26) hand tight. Use...

  • Page 47: Neck Retainer And Locking System

    REASSEMBLY OF THE G3000SS DIVING HELMET IS NOW COMPLETE. PROCEED TO AND COMPLETE PART 3 - HELMET FINAL TESTING SECTION IN CHECKLIST 6 PRIOR TO USE.

  • Page 48: Vii. Technician Check Lists

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual VII. TECHNICIAN CHECK LISTS Checklist 5 G3000SS Diving Helmet Monthly Inspection and Maintenance Checklist Checklist 6 G3000SS Diving Helmet Annual Inspection and Maintenance Checklist...

  • Page 49: Checklist 5 G3000Ss Diving Helmet Monthly Inspection And Maintenance Checklist

    (i.e. ten dives) in any given month. This checklist is to be used in conjunction with the helmet operations and maintenance manual for guidance in conducting each step in the inspection and maintenance of the G3000SS diving helmet. NOTE: •...
  • Page 50 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued) 1. All parts are to be visually inspected for damage or deterioration. 2. Any damaged or defective parts must be replaced. 3. Between annual overhauls certain consumable parts (e.g. o-rings) may be reused if no damage or deterioration is revealed by the inspection process.
  • Page 51 MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS NOSE CLEARING • Check NCD for ease of movement and then remove NCD and check for damage to the DEVICE (NCD) NCD body and components. • Visually inspect o-rings and neoprene pad for damage and/or deterioration and if necessary replace.
  • Page 52 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS HANDWHEEL KNOB • Remove the handwheel knob and check the condition of the guide hole. It should be square and firm. If any deterioration or excess play is present, replace knob.
  • Page 53 NOTE: If regulator performance is suspect, the valve spindle assembly may need to be disassembled and serviced by a trained technician. NOTE: Refer to: Apeks GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL for guidance. HELMET SHELL AND •...

  • Page 54: Checklist 6: G3000Ss Diving Helmet Annual Inspection And Maintenance Checklist

    (i.e. Annual Overhaul) unless daily or monthly inspections reveal the need for this to be conducted more frequently. This checklist is to be used in conjunction with the helmet operations and maintenance manual for guidance in conducting each step in the inspection and maintenance of the G3000SS. NOTE: •...

  • Page 55: Part 1 - Helmet Disassembly

    ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) PART 1 - HELMET DISASSEMBLY Follow Section VI - Step-By-Step Disassembly / Reassembly Procedures along with this Annual Inspection and Maintenance Checklist to disassemble the helmet for annual service and inspection. COMPLETE THE FOLLOWING BOXES PRIOR TO THE CHECKLIST COMPLETE THE SIGNATURE, DATE AND COMMENTS AT THE END OF THE CHECKLIST Helmet Serial No: Date:...
  • Page 56 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS NECK RETAINER AND LOCKING SYSTEM NOTE: Refer to the neck retainer and locking system disassembly section of the operations and maintenance manual for guidance.
  • Page 57 ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS ORAL-NASAL MASK NOTE: Refer to the oral-nasal mask disassembly section of the operations and maintenance manual for guidance. ORAL-NASAL • Remove oral-nasal mask (microphone must be remove prior to oral-nasal mask) and check for damage and/or deterioration.
  • Page 58 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS DOUBLE EXHAUST / WATER DUMP VALVE NOTE: Refer to the double exhaust / water dump valve disassembly section of the operations and maintenance manual for guidance.
  • Page 59 ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS MANIFOLD NOTE: Refer to the manifold disassembly section of the operations and maintenance manual for guidance. MANIFOLD BODY • Remove the manifold body, complete, from the helmet. • Inspect hex screws for damage. CHECK VALVES (2) •...
  • Page 60 APEKS GX300 SECOND STAGE REGULATOR NOTE: Complete service and maintenance instructions for the Apeks GX300 Second Stage Regulator are contained in the separate Apeks document GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL. GX300 REGULATOR CASE •...
  • Page 61 • Blow any moisture out of airway assembly using compressed air. Date: Signature: Technician Comments (e.g. Specific items noted during maintenance): Comments: DISASSEMBLY OF THE G3000SS DIVING HELMET IS NOW COMPLETE. PROCEED TO PART 2 OF THE CHECKLIST FOR REASSEMBLY.

  • Page 62: Part 2 - Helmet Reassembly

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) PART 2 - HELMET REASSEMBLY Follow Section VI - Step-By-Step Disassembly / Reassembly Procedures along with this Annual Inspection and Maintenance Checklist to reassemble the helmet to its original condition.
  • Page 63 ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) FREE FLOW / WATER DUMP VALVE NOTE: Refer to the free flow / water dump valve reassembly section of the operations and maintenance manual for guidance. O-RINGS (3) • Lubricate the o-rings with Cristo-Lube MCG 111. WATER DUMP EXHAUST •...
  • Page 64 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS MANIFOLD NOTE: Refer to the manifold reassembly section of the operations and maintenance manual for guidance. SCREEN • Install the screen in to the manifold body clear- ing the threads and making sure the outlet port is completely covered by the screen.
  • Page 65 ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS DOUBLE EXHAUST / WATER DUMP VALVE NOTE: Refer to the double exhaust / water dump valve reassembly section of the operations and maintenance manual for guidance. AIRWAY • Tighten the swivel nut of the airway onto the Swagelock connector until it bottoms out.
  • Page 66 APEKS GX300 SECOND STAGE REGULATOR NOTE: Complete service and maintenance instructions for the Apeks GX300 Second Stage Regulator are contained in the separate Apeks document GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL. VALVE DIAPHRAGM •...
  • Page 67 ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS COMMUNICATIONS NOTE: Refer to the communications reassembly section of the operations and main- tenance manual for guidance. COMMUNICATIONS • Install a lubricated o-ring onto the comms bulkhead, then screw the bulkhead into the BULKHEAD modified nut in the inside of the helmet shell.
  • Page 68 Install lubricated quad ring into the groove on the upper neck ring. Date: Signature: Technician Comments (e.g. Specific items noted during maintenance): Comments: REASSEMBLY OF THE G3000SS DIVING HELMET IS NOW COMPLETE. PROCEED TO PART 3 OF THE CHECKLIST AND COMPLETE HELMET FINAL TESTING PRIOR TO USE.

  • Page 69: Part 3 - Helmet Final Testing

    ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) PART 3 - HELMET FINAL TESTING Helmet Final Testing is part of the Annual Inspection and Maintenance Procedure and must be completed prior to use. COMPLETE THE FOLLOWING BOXES PRIOR TO THE CHECKLIST COMPLETE THE SIGNATURE, DATE AND COMMENTS AT THE END OF THE CHECKLIST Helmet Serial No: Date: Technician:...
  • Page 70 • Install brass caps onto manifold SCUBA and hose fittings. • Helmet final testing is now complete. THE ANNUAL OVERHAUL OF THE G3000SS DIVING HELMET IS NOW COMPLETE. Date: Signature: Technician Comments (e.g. Specific items noted during maintenance): Comments:...
  • Page 71 FUNCTIONAL BENCH TEST OF THE HELMET AND REGULATOR ("NECK DAM PULL TEST") 1. Connect a regulated air source between 9.2 BAR (133 PSI) and 9.8 BAR (142 PSI) to the helmet. 2. Take hold of the open end of the neck seal and "bunch"...

  • Page 72: Viii. Appendices

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual VIII. APPENDICES Appendix A Main Assemblies Appendix B Inner Components Appendix C Manifold Body Appendix D Free Flow / Water Dump Valve Appendix E Second Stage Regulator Appendix F Nose Clearing Device (NCD)

  • Page 73: Main Assemblies

    APPENDIX A – MAIN ASSEMBLIES SS Blank Plug 90 in lb (10 Nm) 140 in lb (16 Nm) 90 in lb (10 Nm) MANIFOLD SEE APPENDIX C 25 ft lb (34 Nm) 80 in lb (9 Nm) INNER COMPONENTS SEE APPENDIX B SECOND STAGE SEE APPENDIX E 140 in lb (16 Nm)

  • Page 74: Inner Components

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX B – INNER COMPONENTS COMMUNICATIONS KITS SEE APPENDICES L & M VALVE ASSEMBLY PN AP0271 INCLUDES KEY # 36 & 37 45 in lb (5 Nm) KEY # QTY DESCRIPTION...

  • Page 75: Manifold

    APPENDIX C – MANIFOLD 80 in lb (9 Nm) 90 in lb (10 Nm) 80 in lb (9 Nm) 45 in lb (5 Nm) KEY # QTY DESCRIPTION 400036 SCREW, HEX, MANIFOLD (5 PK) 400035 SCREW, HEX, MANIFOLD (5 PK) 400033 INSERT, MANIFOLD 400034...

  • Page 76: Free Flow / Water Dump Valve

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX D – FREE FLOW / WATER DUMP VALVE NOTE: A double exhaust / water dump valve is fitted 35 ft lb (47 Nm) to the G3000SS helmet - See Appendix A.

  • Page 77: Second Stage Regulator

    APPENDIX E – SECOND STAGE REGULATOR NOTE: Complete service and maintenance instructions for the Apeks GX300 Second Stage Regulator are contained in the separate Apeks document GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL.

  • Page 78: Nose Clearing Device (Ncd)

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX F – NOSE CLEARING DEVICE (NCD) KEY # QTY DESCRIPTION 400077 NOSE PAD, NEOPRENE (5 PK) 400140 NOSE CLEARING DEVICE (WELDED) 400074 O-RING, NOSE CLEARING DEVICE (NCD) (10 PK) 400073 KNOB, NCD Part numbers in BOLD ITALICS indicate standard overhaul replacement part.

  • Page 79: Neck Dam

    APPENDIX G – NECK DAM 20 in lb (2 Nm) 20 in lb (2 Nm) 20 in lb (2 Nm) KEY # QTY DESCRIPTION 400078 RING, QUAD 400079 RING, NECK UPPER 400080 SEAL, NECK 400081 RING, NECK LOWER 400082 SCREW, NECK RING LOWER (5 PK) 400085 BUCKLE, STRAP 400084...

  • Page 80: Welding Shield Kit

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX H – WELDING SHIELD KIT 45 in lb (5 Nm) 45 in lb (5 Nm) 45 in lb (5 Nm) 80 in lb (9 Nm) KEY # QTY DESCRIPTION 400089...

  • Page 81: Welding Shield Assembly Installation Instructions

    INSTALLATION INSTRUCTIONS This procedure is to be performed only by personnel who have received appropriate training. If you do not completely understand all of the procedures, contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further.

  • Page 82: Free Flow Plug Insert Kit Installation Instructions

    INSTALLATION INSTRUCTIONS This procedure is to be performed only by personnel who have received appropriate training. If you do not completely understand all of the procedures, contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further.
  • Page 83 FREE FLOW KIT PLUG INSTALLATION INSTRUCTIONS (continued) 6. Remove defogger train (38) 7. Remove free flow barrel (34) 8. Lubricate and install o-ring on from the free flow barrel (34). from the free flow / water dump outside of free flow plug. Place valve assembly.

  • Page 84: Camera / Light Bracket Installation Instructions

    INSTALLATION INSTRUCTIONS This procedure is to be performed only by personnel who have received appropriate training. If you do not completely understand all of the procedures, contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further.

  • Page 85: Terminal Block Communications Kits

    APPENDIX L – TERMINAL BLOCK COMMUNICATIONS KITS TERMINAL BLOCK HI-USE COMMUNICATIONS MODULE KIT (P/N 400150) Hand tight & 1¼ turn with wrench KEY # QTY PART # DESCRIPTION 400122 CAP & PLASTIC FERRULES, BULKHEAD ASSY 400133 TUBING PLASTIC, PRE-CUT (10PK) 400152 WIRE TERMINAL BLOCK 400126...

  • Page 86: Twist-On Communications Kits

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX M – TWIST-ON COMMUNICATIONS KITS TWIST-ON HI-USE COMMUNICATIONS MODULE KIT (P/N 400144) Hand tight & 1¼ turn with wrench KEY # QTY Part # DESCRIPTION 400122 CAP & PLASTIC FERRULES, BULKHEAD ASSY...

  • Page 87: Communications Kit Installation Instructions

    COMMUNICATIONS KIT INSTALLATION INSTRUCTIONS This procedure is to be performed only by personnel who have received appropriate training. If you do not completely understand all of the procedures, contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further.
  • Page 88 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual Wiring Terminal Block for 4-Wire Communications 1. Install connector cable lug rings onto the terminal block (29) per the terminal block pin configuration (Fig. 5) and wiring diagram (Fig. 6). Install the speakers left / right and microphone lug rings onto the terminal block per the wiring diagram.
  • Page 89 5. Install connector cable lug rings onto the com- munication posts (24) per the communication posts pin configuration (Fig. 9) and wiring diagram (Fig. 11). Install the speakers left / right lug rings onto the communication posts per wiring diagram. Securely tighten communication post hex nuts to Figure 9 communication posts with a 3/8"...
  • Page 90 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual Wiring Terminal Block for 2-Wire Communications 1. Install connector cable lug rings onto the terminal block (29) per the terminal block pin configuration (Fig. 14) and wiring diagram (Fig. 15). Install the speakers left / right and microphone lug rings onto the terminal block per the wiring diagram.

  • Page 91: Torque Specifications

    APPENDIX O TORQUE SPECIFICATIONS Part # DESCRIPTION / KEY # TORQUE (IN LB) NOTE 400009 Screw, Exhaust Valve Cover (N/A) 45 in lb (5 Nm) Used in free flow plug insert kit only 400113 Screw, Latch (4) 140 in lb (16 Nm) 400015 Screw, Retainer Port (11) 45 in lb (5 Nm)

  • Page 92: Recommended Cleaners And Lubricants

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX P RECOMMENDED CLEANERS AND LUBRICANTS LUBRICANT/CLEANER APPLICATION SOURCE Aqua Lung Christo-Lube MCG 111 2340 Cousteau Court All o-rings PN 820466 (2 oz.) Vista, Ca 92081 PN 820467 (16 oz.) (760) 597-5000 CAUTION: Silicone rubber requires no lubrication or preservative treatment.

  • Page 93: Cleaning And Lubricating

    APPENDIX Q CLEANING AND LUBRICATING Cleaning Brass and Stainless Steel Parts 1. If required, pre-clean in warm, soapy water* using a nylon bristle tooth brush. 2. Thoroughly clean parts in an ultrasonic cleaner filled with a solution of household white distilled vinegar (acetic acid) mixed with fresh water (max 50% vinegar).

  • Page 94: Annual Service Kit

    NOTE: Refer to APEKS GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL for contents of this kit. NOTE: G3000SS Annual Service Kit w/o regulator (P/N 4000183 ) includes all the parts listed in the table above accept the AP0300/K GX300 regulator service kit.

  • Page 95: Field Spares Kit

    Handwheel Assembly NOTES: 1. The Kit, G3000SS Helmet Field Spares, is intended to provide commonly used spares (i.e.first needs) to support diving using the G3000SS Diving Helmet. 2. The kit contains items that, based on experience, may require replacement during a 12 to 24 month period of use.

  • Page 96: Maintenance Log Sheet

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX T G3000SS MAINTENANCE LOG SHEET...

  • Page 97: Ix. G3000Ss Diving Helmet Spare Parts List

    IX. G3000SS DIVING HELMET SPARE PARTS LIST Part # Description 400001 Shell, Helmet 400003 Bolt, Neck Retainer (5 Pack) 400004 Nut, Neck Retainer (5 Pack) 400005 Spring, Latch (5 pack) 400009 Screw, Exhaust Valve Cover (5 Pack) 400010 Cover, Exhaust Valve...
  • Page 98 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual Part # Description 400045 O-ring, Exhaust (Small) (10 Pack) 400046 O-ring, Exhaust (Large) (10 Pack) 400047 Valve, Water Dump / Flapper Exhaust 400048 Ring, Water Dump / Flapper Valve Snap 400049...
  • Page 99 400151 Comms Module Kit, Terminal Block, Marsh Marine 400152 Wire Terminal Block 400180 Kit, Annual Service, G3000SS 400183 Kit, Annual Service, w/o Regulator G3000SS 400184 Head Liner, Thin 400185 Kit, G3000SS Helmet Field Spares 400192 Screw, Button Cap (5 pack)

  • Page 100: G3000Ss Diving Helmet Accessories

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual X. G3000SS DIVING HELMET ACCESSORIES Switch Block, G3000SS Helmet Side Block, G3000SS P/N AP0281/G P/N AP0281/SB Adjustable Pressure Relief Valve Flow Restrictor (APRV) (for suit inflation port) P/N AP0849K P/N AP0730...
  • Page 101 Bailout Hose Assembly w/ (QD) P/N 400161 Accessory Rail P/N 400195 Universal Side Mount P/N 400196 • P/N 400167 - Hose Assy, LP, 33", w/ QD, Yellow P/N 400168 - Hose Assy, LP, 6", w/ QD, Yellow • P/N 400162 - Hose Assy, LP, 33", 1/4" MNPT, Yellow P/N 400163 - Hose Assy, LP, 6", 1/4"...
  • Page 102 AQUA LUNG G3000SS HELMET OPERATIONS & MAINTENANCE MANUAL 2340 Cousteau Court • Vista, CA 92081 Phone (760) 597-5000 • Fax (760) 597-4900 www.aqualung.com/militaryandprofessional www.gorskihat.com ©2018 Aqua Lung International...

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