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

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AQUA LUNG G3000SS HELMET
OPERATIONS & MAINTENANCE MANUAL

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  • Page 1 AQUA LUNG G3000SS HELMET OPERATIONS & MAINTENANCE MANUAL...
  • 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 ..............................10 CHECKLIST 1: G3000SS Diving Helmet Daily Checklist ..................11 CHECKLIST 2: G3000SS Diving Helmet Pre-Dive Checklist ..................15 CHECKLIST 3: G3000SS Diving Helmet In-Water Checklist for Supervisor ............18 CHECKLIST 4: G3000SS Diving Helmet Post-Dive Checklist ..................20 TECHNICAL SECTION V.
  • Page 4 K. Helmet Final Assembly ............................39 L. Neck Dam Assembly ..............................44 VII. TECHNICIAN CHECKLISTS ............................45 CHECKLIST 5: G3000SS Diving Helmet Monthly Inspection and Maintenance Checklist ........46 CHECKLIST 6: G3000SS Diving Helmet Annual Inspection and Maintenance Checklist ........51 VIII. APPENDICES ................................60 A. Main Assemblies ..............................61 B.

  • Page 5: 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 6: Operations Section

    Breathing loop components protected inside shell. • Low component count. • Reduced maintenance load. The G3000SS has many components in common with the original Gorski G2000SS helmet but with the following important revisions: • Apeks GX300 2nd stage regulator. •...

  • Page 7: Dive System Requirements

    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. • Emergency Gas Supply (EGS) or bailout gas supply (including 1st stage regulator fitted with pressure gauge, and pressure relief valve).

  • Page 8: 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 9: Head Protection

    Decompression diving always involves the risk of decompression illness. Omitted decompression due to a loss of the breathing gas supply or other incident may lead to serious injury or death. Use of a G3000SS helmet mask cannot prevent this type of injury.

  • Page 10: User Checklists

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual IV. USER CHECKLISTS Checklist 1 G3000SS Diving Helmet Daily Checklist 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”...

  • Page 11: 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 12 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual 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.
  • Page 13 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. NOTE: Ensure that the EGS •...
  • Page 14 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual 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) •...

  • Page 15: 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 16 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual 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 •...
  • Page 17 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. • Neck dam is installed. WARNING: Both latch •...

  • Page 18: 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 19 IN-WATER CHECKLIST (continued) APEKS GX300 REGULATED SUPPLY PRESSURE TABLE NOTE: The main objective of the regulated supply pressures listed in the table below is to ensure that a pressure between 8.9 and 10.3 bar above ambient pressure is maintained at the diver as tested and CE certified.

  • Page 20: 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 21 NOTE: Refer to the separate Apeks Technical Manual: GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL for guidance on installation and removal of the regulator. NOTE: The GX300 regulator valve cover and exhaust valve assembly should be removed and rinsed carefully with fresh water after diving in extreme conditions (e.g.
  • Page 22 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual 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. Dry the inside of the helmet, including oral-nasal mask, by wiping. If required, wash with soap and water, rinse with fresh water and allow to dry.

  • Page 23: 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 24: 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 25: Step-By-Step Assembly Instructions

    VI. STEP-BY-STEP ASSEMBLY INSTRUCTIONS 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 ASSEMBLY Disassembly procedures are the reverse of assembly.

  • Page 26: Second Stage Regulator

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual SECOND STAGE REGULATOR The G3000SS Diving Helmet is fitted with the Apeks GX300 Second Stage Regulator (P/N AP0300). 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 27: Free Flow / Water Dump Valve

    FREE FLOW / WATER DUMP VALVE Step 1: Breakdown of free flow/ Step 2: Install small o-ring (51) Step 3: O-ring (51) installed on water dump valve parts. onto valve body (52). valve body (52). Step 4: Install o-ring (53) onto the Step 5: Put flapper exhaust valve Step 6: Flapper exhaust valve valve body (52) groove.
  • Page 28 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual FREE FLOW / WATER DUMP VALVE (continued) Step 10: Thread in the valve seat Step 11: Place two copper washers Step 12: Place o-ring (59) into (55) with valve stem (57).

  • Page 29: Manifold

    MANIFOLD Step 1: Break down of manifold Step 2: Insert screen (44) into the Step 3: Line up screen (44) with assembly. manifold body (45). Failure to install the end of threads in the manifold may cause debris to block the flow body (45).

  • Page 30: Defogger

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual DEFOGGER Step 1: Two parts of defogger Step 2: Insert lower unit over Step 3: Push lower unit until it train (36), lower and upper unit. the free flow / water dump valve stops.

  • Page 31: Oral-Nasal Mask

    (35). NOTE: Refer to the separate Apeks Technical Manual: GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL for guidance on installation of the regulator. NOTE: Inhalation valve must be installed on the inside of the oral-nasal mask. If...
  • Page 32 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual ORAL-NASAL MASK (continued) Step 9: Install oral-nasal mask (37) Step 7: Install microphone Step 8: Point microphone wire onto the regulator mouthpiece. (30) in the right pocket of the downwards. oral-nasal mask (37).

  • Page 33: Nose-Clearing Device (Ncd)

    NOSE-CLEARING DEVICE (NCD) Step 1: Breakdown of nose clearing Step 2: Install two o-rings (63) Step 3: O-rings (63) installed. device parts. into the grooves on the NCD shaft (62) using o-ring pick. Step 4: Place neoprene nose pad Step 5: Fold over and press the (61) over nose cleaning device pad ends together.

  • Page 34: Face Port Assembly

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual FACE PORT ASSEMBLY Step 1: Place o-ring (14) in the Step 2: O-ring (14) installed in Step 3: Place face port (13) into port groove. port groove. the helmet shell (1).

  • Page 35: Communications

    NOTE: The G3000SS helmet is supplied with a 4-wire communications system or 2-wire communications system. Helmets may be converted easily from one to the other. Refer to Appendix N for wiring schematic diagrams and instructions.

  • Page 36: Head Liner

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual HEAD LINER CAUTION: The head liner and oral-nasal mask must be used at all times when diving. The head liner ensures that the oral-nasal mask maintains a good fit on the diver’s face and reduces dead space in the helmet, this helps to prevent CO2 build-up.

  • Page 37: Neck Retainer And Locking System

    NECK RETAINER AND LOCKING SYSTEM Step 1: Breakdown of locking Step 2: Insert left latch (2) or right Step 3: Latch inserted in latch system parts. latch (3) into corresponding latch base. base left (6) or latch base right (7). Note: There are left and right latch catch assemblies Step 4: Fit latch spring (8) over shaft...
  • Page 38 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual NECK RETAINER AND LOCKING SYSTEM (continued) Step 10: Insert latch screw (4) and Step 11: Tighten latch screw (4) Step 12: Repeat the procedure latch spring washer (5) through using a 1/4" hex key to 140 in.lbs for the other latch.

  • Page 39: Helmet Final Assembly

    Step 4: Install second stage into NOTE: Refer to the separate Apeks Technical Manual: opposite side. GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL for guidance on installation of the regulator. Step 5: Place o-ring (33) on...
  • Page 40 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual HELMET FINAL ASSEMBLY (continued) Step 8: Airway assembly (29). Step 9: Stick open end of airway Step 10: Press airway assembly assembly into swagelock con- (29) inside the helmet shell (1).
  • Page 41 11/16" open end wrench. NOTE: Refer to the separate Apeks Technical Manual: GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL for guidance on installation of the regulator. Step 20: Dual exhaust bushing...
  • Page 42 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual Step 23: Place all spacer rings (17) Step 24: Spacer rings (17) in place. Step 25: Place exhaust valve cover onto the dual exhaust seat (16). (19) on top of spacer rings (17).
  • Page 43 Short Screw Long Screw Step 32: Line up assembled Step 33: Use longer manifold Step 34: Tighten the longer manifold body (45) with the hex screws (10) on left side and manifold screws (10) manifold insert (40) and holes. short manifold hex screws (39) onto inner airway bracket on right side.

  • Page 44: Neck Dam Assembly

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual ORAL / NASAL ASSEMBLY Step 41: Install nose clearing device Step 42: Screw NCD knob (64) Step 43: NCD installed outside (62) through the inside of helmet into the nose clearing device (62).

  • Page 45: Technician Checklists

    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 46: 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 47 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 dam- age or deterioration is revealed by the inspection process.
  • Page 48 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS COMMUNICATIONS • Without removing the comms system, check condition of speakers and microphone by visual inspection. If inspection reveals poor quality of sound, replace with new speakers and/or microphone.
  • Page 49 NOTE: Refer to: Apeks GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HEL- MET - MAINTENANCE MANUAL for guidance. FREE FLOW VALVE • Remove the handwheel knob and check the condition of the guide hole.
  • Page 50 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS FREE FLOW / WATER • Remove the exhaust valve cover and without removing the free flow / water dump valve from DUMP VALVE the helmet, remove the snap ring and flapper valve.

  • Page 51: 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 52 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) DISASSEMBLY - SEQUENCE OF EVENTS This sequence is for guidance. Maintenance instructions are located in Section VI-Step-By-Step Assembly Instructions of the Operations and Maintenance Manual.
  • Page 53 ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) 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: (Print Name) STEPS PROCEDURE INITIALS NECK DAM ASSEMBLY NOTE: Refer to the neck dam assembly section of the Operations and Maintenance Manual for guidance.
  • Page 54 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 section of the Operations and Maintenance Manual for guidance. LATCH CATCHES •...
  • Page 55 ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS ORAL-NASAL MASK NOTE: Refer to the oral-nasal mask 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 56 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 •...
  • Page 57 ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS FREE FLOW / WATER DUMP VALVE AND DEFOGGER NOTE: Refer to the free flow / water dump valve and defogger section of the Operations and Maintenance Manual for guidance. FREE FLOW / WATER •...
  • Page 58 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS FREE FLOW VALVE • Check condition of the guide hole in the knob. It should be square and firm. If any deterioration or KNOB excess play is present, replace knob.
  • Page 59 ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS FACE PORT ASSEMBLY NOTE: Refer to the face port assembly section of the Operations and Maintenance Manual for guidance. PORT RETAINER • Visually inspect the port retainer and screws for damage. •...

  • Page 60: Appendices

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

  • Page 61: Main Assemblies

    APPENDIX A – MAIN ASSEMBLIES 140 in.lbs (16 Nm) 25 ft.lbs (34 Nm) SS Blank Plug 90 in.lbs (10 Nm) MANIFOLD BODY ASM SEE APPENDIX C 80 in.lbs (9 Nm) INNER COMPONENTS SEE APPENDIX B SECOND STAGE ASM SEE APPENDIX E NOSE CLEARING 140 in.lbs (16 Nm) DEVICE ASM SEE...

  • Page 62: 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 # 34 & 35 45 in.lbs (5 Nm) KEY # QTY DESCRIPTION 400130...

  • Page 63: Manifold Body Assembly

    APPENDIX C – MANIFOLD BODY ASSEMBLY 80 in.lbs (9 Nm) 90 in.lbs (10 Nm) 80 in.lbs (9 Nm) 45 in.lbs (5 Nm) KEY # QTY DESCRIPTION 400036 SCREW, HEX, MANIFOLD (5 PK) 400035 SCREW, HEX, MANIFOLD (5 PK) 400033 INSERT, MANIFOLD 400034 O-RING, MANIFOLD CONNECTOR (10 PK) 400037...

  • Page 64: Free Flow / Water Dump Valve Assembly

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

  • Page 65: Second Stage Regulator Assembly

    APPENDIX E – SECOND STAGE REGULATOR ASSEMBLY 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 66: Nose Clearing Device (Ncd) Assembly

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX F – NOSE CLEARING DEVICE (NCD) ASSEMBLY KEY # QTY DESCRIPTION 400077 NOSE PAD, NEOPRENE (5 PK) 400140 NOSE CLEARING DEVICE (WELDED) 400074 O-RING, NOSE CLEARING DEVICE (NCD) (10 PK)

  • Page 67: Neck Dam Assembly

    APPENDIX G – NECK DAM ASSEMBLY 20 in.lbs (2 Nm) 20 in.lbs (2 Nm) 20 in.lbs (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 68: Welding Shield Kit

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX H – WELDING SHIELD KIT 45 in.lbs (5 Nm) 45 in.lbs (5 Nm) 45 in.lbs (5 Nm) 80 in.lbs (9 Nm) KEY # QTY DESCRIPTION 400089 BRACKET, LENS HOLDING (2 PK)

  • Page 69: 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 procedure, contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further.

  • Page 70: 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 procedure, contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further.
  • Page 71 FREE FLOW KIT PLUG INSTALLATION INSTRUCTIONS (continued) Step 6: Remove defogger train Step 7: Remove free flow barrel Step 8: Lubricate and install o-ring (36). (32). on outside of free flow plug. Place hook and loop strip on barrel. Step 9: Install free flow plug in Step 10: Replace regulator cover.

  • Page 72: 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 procedure, contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further.

  • Page 73: 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 74: 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 75: 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 procedure, contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further.
  • Page 76 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 (83) 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 77 3. 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 78 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 (83) 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 79: Torque Specifications

    APPENDIX O TORQUE SPECIFICATIONS Part # DESCRIPTION / KEY # TORQUE (IN.LBS) NOTE 40009 Screw, Exhaust Valve Cover (N/A) 45 in.lbs (5 Nm) Used in Free Flow Plug Insert Kit only 400113 Screw, Latch (4) 140 in.lbs (16 Nm) 400015 Screw, Retainer Port (11) 45 in.lbs (5 Nm) 400021...

  • Page 80: Recommended Cleaners And Lubricants

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual APPENDIX P RECOMMENDED CLEANERS AND LUBRICANTS LUBRICANT/CLEANER APPLICATION SOURCE Aqua Lung, PN 820466 (2 oz.) 820467 (16 oz.), or Christo-Lube MCG 111 Lubrication Technologies All o-rings 310 Morton Street Jackson, OH 45640...

  • Page 81: 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 82: Annual Service Kit

    O-ring, Stem, Free Flow / Water Dump Valve 400074 O-ring, Nose Clearing Device (NCD) AP0300/K GX300 Regulator Service Kit See Note NOTE: Refer to APEKS GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL for contents of this kit.

  • Page 83: G3000Ss Diving Helmet Spare Parts List

    IX. G3000SS DIVING HELMET SPARE PARTS LIST Part # Description 400300 Helmet, G3000SS, w/ 2-wire comms 400301 Helmet, G3000SS, w/ 4-wire comms, Hi-Use 400302 Helmet, G3000SS, w/ 4-wire comms, Marsh Marine 400001 Shell, Helmet 400003 Bolt, Neck Retainer (5 Pack)
  • Page 84 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 85 Part # Description 400122 Cap & Ferrules, Bulkhead Assy 400123 Nose Clearing Device, Assy 400124 Head Liner, Thick 400125 Cable Assy OTS Comm, Marsh Marine 400126 Cable Assy, OTS Comm, High-Use 400127 Ferrules, Nylon (10 pack) 400128 Blank Plug, SS 400129 Speaker, Left 400130...

  • Page 86: G3000Ss Diving Helmet Accessories

    Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual X. G3000SS DIVING HELMET ACCESSORIES Switch Block, G3000SS P/N AP0281/G Helmet Flotation Bag P/N 400805 Standard Helmet Bag P/N 400804 Bailout Hose Assembly w/ (QD) P/N 400161 • Hose Assy, LP, 33", w/ QD, Yellow P/N 400167 Hose Assy, LP, 6", w/ QD, Yellow P/N 400168...
  • Page 87 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 Literature P/N 400179 Rev. 5/14 ©2014 Aqua Lung International...

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