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Aqua Lung G3000SS, Operation & Maintenance Manual

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Aqua Lung G3000SS Operation & Maintenance Manual Download Page 62

APPENDIX B – INNER COMPONENTS

KEY # QTY

P/N

DESCRIPTION

28

1

400130

SPEAKER RIGHT

29

1

400138

AIRWAY ASSEMBLY

30

1

400131

MICROPHONE

31

1

400021

SWAGELOCK CONNECTOR

32

1

400024

BARREL, FREE FLOW

33

1

400022

O-RING, SWAGELOCK CONN & PORT PLUG (10 PK)

34

1

AP6223

VALVE, INHALATION

35

1

AP2537

HOUSING, INHALATION VALVE

36

1

400023

TRAIN, DEFOGGER

37

1

400025

MASK, ORAL NASAL

38

1

400129

SPEAKER LEFT

N/S

1

400028

HEAD LINER

83

1

400152

WIRE TERMINAL BLOCK

Part numbers in 

BOLD ITALICS 

indicate standard overhaul replacement part.

28

29

30

32

33

36

37

31

45 in.lbs (5 Nm)

34

35

VALVE ASSEMBLY PN AP0271 

INCLUDES KEY # 34 & 35

38

COMMUNICATIONS KITS 

SEE APPENDICES L & M

83

62   

 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

Summary of Contents for G3000SS

Page 1: ...AQUA LUNG G3000SS HELMET OPERATIONS MAINTENANCE MANUAL AQUA LUNG G3000SS DIVING HELMET www aqualung com militaryandprofessional...

Page 2: ...t PN 400300 PN 400301 PN 400302 You can contact a Technical Advisor via e mail at sreilly aqualung com lgorski aqualung com Trademark Notice Aqua Lung is a registered trademark of Aqua Lung America In...

Page 3: ...ure 8 Head Protection 9 Use with Low Pressure Oxygen 9 Environmental Conditions 9 G2000SS Helmet Conversion 9 IV USER CHECKLISTS 10 CHECKLIST 1 G3000SS Diving Helmet Daily Checklist 11 CHECKLIST 2 G30...

Page 4: ...ance Checklist 51 VIII APPENDICES 60 A Main Assemblies 61 B Inner Components 62 C Manifold Body Assembly 63 D Free Flow Water Dump Valve Assembly 64 E Second Stage Regulator Assembly 65 F Nose Clearin...

Page 5: ...ous condition and can lead to a loss of reasoning ability decreased manual dexterity uncontrollable shivering unconsciousness and death II WARRANTY INFORMATION The manufacturer warrants every new helm...

Page 6: ...rmance requirements at all required standard and high RMV work rates Meets inspired partial pressure of carbon dioxide performance requirements at all required standard and high RMV work rates Is test...

Page 7: ...Users must be aware of the potential for obstruction of the helmet manifold if the bailout system is rigged in the cylinder Valve Up configuration BAILOUT CONFIGURATIONS There are 2 standard equipment...

Page 8: ...s follows Maximum noise level at 40 l min RMV 83 4 dB A Limit 85 dB A re 204Pa Maximum noise level at 75 l min RMV 98 3 dB A Limit 135 dB A re 204Pa Maximum permissible noise exposure times are to be...

Page 9: ...00SS diving helmet to a G3000SS diving helmet the following items are needed PN AP0300 Apeks GX300 Regulator PN AP0270 Handwheel Assembly PN 400111 Double Exhaust Water Dump Kit PN 400150 Terminal Blo...

Page 10: ...r 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 hoo...

Page 11: ...200 psig 12 4 13 8 BAR WARNING Aqua Lung strongly recommends completion of this checklist and meeting the minimum requirements provided before using the G3000SS diving helmet However these requirement...

Page 12: ...OTE If a contaminated area of the shell is cleaned using a wire brush the brush must be stainless steel or the area will be contaminated Inspect the oral nasal inhalation valve to ensure that it is in...

Page 13: ...en proceed as follows DIRECT BAILOUT CONFIGURATION Connect the regulator hose directly to the helmet check valve BAILOUT SWITCH BLOCK CONFIGURATION Connect the regulator hose to the bailout inlet conn...

Page 14: ...UNICATIONS to be completed by diver Check all communications to confirm correct functioning CHECK DRY SUIT INFLATION HOSE must be completed by tender If fitted confirm the dry suit inflation valve and...

Page 15: ...ompletion of this checklist and meeting the minimum requirements provided before using the G3000SS diving helmet However these requirements are not conclusive as further steps may be required dependin...

Page 16: ...ck EGS for leaks Check adjustment or fit of entire helmet including the divers safety harness umbilical strain release EGS hose quick disconnect boots gloves knife and accessories EGS FUNCTIONAL CHECK...

Page 17: ...s L and R engaged on neck retainer Chin strap properly fastened Check adjustment and fit of the diver s safety harness Umbilical strain release EGS hose quick disconnect boots gloves etc Ensure helmet...

Page 18: ...her steps may be required depending on the type of activity performed FAILURE TO COMPLY WITH THIS CHECKLIST MAY RESULT IN SERIOUS INJURY OR EVEN DEATH CAUTION When using the G3000SS diving helmet a co...

Page 19: ...em is used the information in the regulated supply pressure table does not apply The HP gas supply system will automatically adjust the diver s gas supply pressure with changes in depth Always refer t...

Page 20: ...ends completion of this checklist and meeting the minimum requirements provided before using the G3000SS diving helmet However these requirements are not conclusive as further steps may be required de...

Page 21: ...rioration If the head liner is wet air dry it NOTE The head liner may be washed as required 6 If required and particularly if the inside of the regulator was exposed to salt or contaminated water remo...

Page 22: ...emove any standing water and allow to air dry DO NOT STORE A WET HELMET OR COMPONENTS 12 Wash the outside of all EGS components gas cylinder submersible pressure gauge and the harness assembly with so...

Page 23: ...al advisor before proceeding any further SCHEDULED SERVICE 1 The G3000SS Diving Helmet is subject to annual service regardless of usage 2 TheAnnual Inspection and Maintenance Checklist must be followe...

Page 24: ...ated and not allowed to intermix with non reusable parts Delicate parts including inlet fittings and crowns which contain critical sealing surfaces must be protected and isolated form other parts to p...

Page 25: ...cket and Driver 5 8 Flat OE Low Profile Slim Wrench 7 8 Deep Socket and Driver 11 16 Flat OE Low Profile Slim Wrench Torque Screwdriver 20 140 inch pounds O Ring Tool Brass or plastic Torque Wrench 10...

Page 26: ...age Regulator are contained in the separate Apeks document GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET MAINTENANCE MANUAL The above named manual forms part of the formal support documentat...

Page 27: ...1 installed on valve body 52 Step 4 Install o ring 53 onto the valve body 52 groove Step 5 Put flapper exhaust valve 18 on the valve body 52 Step 6 Flapper exhaust valve 18 installed on valve body 52...

Page 28: ...7 into the valve body 52 over the seat 55 Step 15 Place the valve bonnet assembly over the valve stem 57 into the valve body 52 Step 16 Thread the valve bonnet 60 into the valve body 52 Step 17 Tighte...

Page 29: ...33 onto port plug 46 Using a 3 16 hex key screw the port plug to the manifold body 45 Step 7 Tighten port plug 46 with a 3 16 hex key until to 45 in lbs 5 Nm Step 8 Screw check valve 47 with Teflon ta...

Page 30: ...ep 2 Insert lower unit over the free flow water dump valve body Step 3 Push lower unit until it stops Step 4 Align upper unit with the lower unit Step 5 Slide upper unit over the bracket of the lower...

Page 31: ...tion valve housing 35 Step 6 Insert second stage regulator into the helmet shell 1 CAUTION The head liner and oral nasal mask must be used at all times when diving The head liner ensures that the oral...

Page 32: ...NCD shaft 62 Ensure that it is snug Step 12 Always check before diving to ensure that no threads are visible in order to prevent loosing the knob 64 Step 13 Inside view of installed oral nasal mask a...

Page 33: ...ring device parts Step 2 Install two o rings 63 into the grooves on the NCD shaft 62 using o ring pick Step 3 O rings 63 installed Step 4 Place neoprene nose pad 61 over nose cleaning device 62 as sho...

Page 34: ...port retainer 12 over face port 13 and line up holes Step 6 Install bottom screw 11 in the port retainer 12 with a Phillips 3 screwdriver Step 7 Install top screw 11 in port retainer 12 all holes shou...

Page 35: ...install all terminals to the internal posts using a 3 8 nut driver Step 4 Install microphone 30 in the right pocket of the oral nasal mask 37 Step 5 Microphone 30 installed in oral nasal mask 37 Step...

Page 36: ...sshown Step 7 Place left speaker 38 in left pocket of head liner Step 8 Place right speaker 28 in right pocket of head liner Step 9 Head liner installed into helmet shell 1 No oral nasal mask fitted C...

Page 37: ...ch base Step 4 Fit latch spring 8 over shaft of left latch 2 or right latch 3 Step 5 Fit latch spring washer 9 onto manifold hex screw 10 Step 6 Insert manifold hex screw 10 and washer 9 into shaft of...

Page 38: ...ch assembly Step 14 Check condition of neck retainer 21 Step 16 Ensure that the neck retainer and locking system mate correctly Step 15 Place the neck retainer 21 to the hinge at rear of helmet shell...

Page 39: ...e Step 5 Place o ring 33 on swagelock connector 31 Step 6 Screw connector into free flow water dump valve body 52 Step 7 Tighten swagelock connector 31 into free flow water dump valve body 52 using 5...

Page 40: ...rway assembly 29 to the back wall of the helmet shell 1 Step 12 Manifold connecting insert 40 and o rings 41 Step 13 Place o rings 41 in both grooves of the manifold insert 40 Step 14 Manifold connect...

Page 41: ...Place dual exhaust seat 16 over the dual exhaust bushing 15 Step 22 Place water dump flapper exhaust valve 18 onto the dual exhaust seat 16 DO NOT LUBRICATE Step 19 Place dual exhaust bushing 15 over...

Page 42: ...ve cover 19 on top of spacer rings 17 Step 26 Insert retainer port screws 11 and tighten by hand Step 27 Tighten screws 11 using a Phillips 3 screwdriver to 45 in lbs 5 Nm Step 28 Place handwheel knob...

Page 43: ...2 on the neck retainer bolt 23 Step 40 Use a 3 16 hex key to hold the bolt 23 and 7 16 nut driver to hold the nut 22 Tighten until the nut touches the hinge Adjust as required Note Ensure that neck re...

Page 44: ...1 Lightly lubricate quad ring 65 and install in groove of upper neck ring 66 Step 2 Check operation of both latch assemblies Photos shows neck retainer with right latch catch open Step 2 Quad ring 65...

Page 45: ...VII TECHNICIAN CHECK LISTS Checklist 5 G3000SS Diving Helmet Monthly Inspection and Maintenance Checklist Checklist 6 G3000SS Diving Helmet Annual Inspection and Maintenance Checklist 45...

Page 46: ...understand all of the procedures outlined in this checklist contact Aqua Lung to speak with a technical advisor before proceeding any further If the helmet is used in contaminated water monthly inspec...

Page 47: ...deterioration A damaged neck seal must be replaced If the quad ring is dry lightly lubricate the quad ring Replace the neck dam assembly onto the helmet and ensure a proper fit NOTE Refer to the neck...

Page 48: ...d if necessary replace Lubricate o rings lightly as required NOTE Refer to the nose clearing device section of the Operations and Maintenance Manual for guidance ORAL NASAL MASK Remove oral nasal mask...

Page 49: ...gulator case Adjust the lever as required and check regula tor adjustment refer to Apeks GX300 Technical Manual Complete the reassembly of the regulator and fit the regulator back into the helmet NOTE...

Page 50: ...ifold plug and clean the manifold screen Replace on completion Check both one way valves for proper operation by sucking on the umbilical and scuba hose adapters NOTE Refer to the manifold section of...

Page 51: ...pletion of this checklist and meeting the minimum requirements provided before using the G3000SS helmet However these requirements are not conclusive as further steps may be required depending on the...

Page 52: ...and short 39 manifold hex screws 3 16 Allen Hex Key 13 Remove the manifold body 45 from the helmet shell 1 No Tools Required 14 Remove the manifold insert 40 No Tools Required 15 Using screwdriver sl...

Page 53: ...uts and or deterioration If necessary replace the quad ring NOTE The quad ring has a long service life and is not normally replaced annually NECK SEAL Visually inspect for cuts and or deterioration If...

Page 54: ...er section of the Operations and Maintenance Manual for guidance HEAD LINER Remove head liner from helmet Visually inspect for deterioration and or damage If necessary replace with a new liner NOTE Th...

Page 55: ...nhalation valve housing INHALATION VALVE one way valve Remove and visually inspect for damage and deterioration Replace the inhalation valve annually COMMUNICATIONS NOTE Refer to the communications se...

Page 56: ...CEDURE INITIALS 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 REGU...

Page 57: ...UMP EXHAUST FLAPPER VALVES Visually inspect for cuts and damage Wash with soap and water rinse with fresh water and allow to dry If necessary replace water dump exhaust flapper valve NOTE The flapper...

Page 58: ...and adapters Confirm correct operation of both check valves by conducting a suck and blow check on each Air should only flow in one direction If this does not happen replace check valve O RINGS 2 Repl...

Page 59: ...ort it will weaken it HELMET SHELL Verify condition and inspect for damage to the helmet shell Clean as required with soap and water rinse with fresh water and dry Blow any moisture out of airway asse...

Page 60: ...Shield Assembly Installation Instructions Appendix J Free Flow Plug Insert Kit Installation Instructions Appendix K Camera Light Bracket Installation Instructions Appendix L Terminal Block Communicat...

Page 61: ...B HANDWHEEL 20b 1 N A SPRING 20c 1 N A NUT 21 1 400114 RETAINER NECK MOD 1 22 1 400004 NUT NECK RETAINER 5 PK 23 1 400003 BOLT NECK RETAINER 5 PK 24 2 400016 POST COMMUNICATION ASSEMBLY 25 1 400017 BU...

Page 62: ...INHALATION 35 1 AP2537 HOUSING INHALATION VALVE 36 1 400023 TRAIN DEFOGGER 37 1 400025 MASK ORAL NASAL 38 1 400129 SPEAKER LEFT N S 1 400028 HEAD LINER 83 1 400152 WIRE TERMINAL BLOCK Part numbers in...

Page 63: ...E 26 1 400031 O RING MANIFOLD PLUG 10 PK 44 1 400032 SCREEN 45 1 400029 BODY MANIFOLD 33 1 400022 O RING SWAGELOCK CONN PORT PLUG 10 PK 46 1 400039 PORT PLUG 47 2 400040 VALVE CHECK 48 1 400041 FITTIN...

Page 64: ...EE FLOW WATER DUMP VALVE 56 2 400050 WASHER COPPER 5 PK 57 1 400051 STEM FREE FLOW WATER DUMP VALVE 58 1 400053 WASHER TEFLON 5 PK 59 1 400052 O RING FREE FLOW WATER DUMP VALVE STEM 10 PK 60 1 400054...

Page 65: ...TOR 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...

Page 66: ...tandard overhaul replacement part 61 62 63 63 64 KEY QTY P N DESCRIPTION 61 1 400077 NOSE PAD NEOPRENE 5 PK 62 1 400140 NOSE CLEARING DEVICE WELDED 63 2 400074 O RING NOSE CLEARING DEVICE NCD 10 PK 64...

Page 67: ...67 1 400080 SEAL NECK 68 1 400081 RING NECK LOWER 69 18 400082 SCREW NECK RING LOWER 5 PK 70 2 400085 BUCKLE STRAP 71 2 400084 BUSHING BUCKLE STRAP 5 PK 72 2 400083 SCREW BUCKLE STRAP 5 PK 73 1 400086...

Page 68: ...K 11 1 400015 SCREW RETAINER PORT 5 PK 78 1 400095 SHIELD WELDING SPRING 79 2 400093 SCREW HINGE BLOCK MOUNTING 5 PK 80 2 400094 SCREW HINGE 5 PK 81 1 400087 BODY WELDING SHELL SHIELD 39 2 400035 SCRE...

Page 69: ...m Step3 Lineupweldinglensassembly Step 4 Secure and tighten left and right hinge block mounting screws 79 to 45 in lbs 5 Nm Step 5 Secure and tighten left and right hinge screws 80 to 45 in lbs 5 Nm S...

Page 70: ...t all times throughout the dive in order to maintain constant air flow The helmet should be fitted with a double exhaust when used for contaminated water diving KIT CONTENTS Part Item Description Qty...

Page 71: ...1 Ensure hook and loop strip is facing inward Step 10 Replace regulator cover Step 11 Tighten exhaust valve cover screws using a Phillips 3 screwdriver to 45 in lbs 5 Nm Step 12 Place hook and loop t...

Page 72: ...ep 1 Remove two retainer port screws 11 from top corner of helmet using a Phillips 3 screwdriver Step 2 Line up bracket holes with helmet retainer holes Step 3 Replace the two retainer port screws 11...

Page 73: ...HEAD ASSY 82 1 400133 TUBING PLASTIC PRE CUT 10PK 83 1 400152 WIRE TERMINAL BLOCK 84 1 400126 CABLE ASSY OTS COMS HI USE KEY QTY PART DESCRIPTION 27 1 400122 CAP PLASTIC FERRULES BULKHEAD ASSY 82 1 40...

Page 74: ...7 1 400146 CABLE ONLY ASSY TWIST ON HI USE KEY QTY Part DESCRIPTION 27 1 400122 CAP PLASTIC FERRULES BULKHEAD ASSY 86 2 400148 TWIST ON CONN KIT 2 CONNS ALONE 88 1 400147 CABLE ONLY ASSY TWIST ON MARS...

Page 75: ...ugh the holes in the terminal block 83 with the U shape of the block facing up Fig 1 Secure the terminal block to the helmet shell with a 3 8 nut driver and one hex nut per communication post Fig 2 2...

Page 76: ...6 Figure 5 CAUTION DO NOT overtighten the communication post hex nuts to the terminal block Installing Cable Assembly 1 Insert the connector cable assembly 87 or 88 into the bulkhead cap and ferrules...

Page 77: ...e microphone 30 to the connector cable assembly 87 or 88 per the wiring diagram Fig 11 Place stripped wires together with the ends of insulation even Twist connector 86 Fig 10 onto wires pushing firml...

Page 78: ...ication post hex nuts to terminal block with a 3 8 nut driver Figure 14 Mic Speaker right Speaker left Figure 15 2 Hi Use pin configuration Fig 16 and Marsh Marine pin configuration Fig 17 Mic Speaker...

Page 79: ...lbs 2 Nm 400083 Screw Buckle Strap 72 20 in lbs 2 Nm 400093 Screw Hinge Block Mounting 79 45 in lbs 5 Nm 400094 Screw Hinge 80 45 in lbs 5 Nm 400128 Blank Plug N A 90 in lbs 10 Nm Part DESCRIPTION KEY...

Page 80: ...general cleaning solution for plastic and rubber Household grade CAUTION Silicone rubber requires no lubrication or preservative treatment DO NOT apply grease or spray to silicone rubber parts Doing s...

Page 81: ...ely to ensure proper cleaning and like new condition Cleaning Plastic Rubber Parts Parts made of plastic or rubber may be soaked and cleaned in a solution of warm water mixed with mild dish soap Use o...

Page 82: ...it Key 400004 Nut Neck Retainer 1 22 400012 O ring Face Port 1 14 400022 O ring Swagelock Connector Port Plug 2 33 AP6223 Valve Flapper Inhalation 1 34 400031 O ring Manifold Plug 2 26 400034 O ring M...

Page 83: ...bly 400018 Bulk Head Communications w Installation 400021 Connector Swagelock 400022 O ring Swagelock Conn Port Plug 10 Pack 400023 Train Defogger 400024 Barrel Free Flow 400025 Mask Oral Nasal AP2537...

Page 84: ...Strap 5 Pack 400084 Bushing Buckle Strap 5 Pack 400085 Buckle Strap 400086 Strap Nylon w D Rings 400087 Body Welding Shell Shield 400088 Lens Welding 400089 Bracket Lens Holding 2 Pack 400090 Gasket W...

Page 85: ...ght 400133 Tubing Plastic Pre Cut 10 pack 400134 Lock Washer 5 16 5 pack 400138 Airway Assembly 400139 Inset Manifold Complete 400140 Nose Clearing Device Welded 400142 Nut Packing 400144 Comms Module...

Page 86: ...1 Hose Assy LP 33 w QD Yellow P N 400167 Hose Assy LP 6 w QD Yellow P N 400168 HoseAssy LP 33 1 4 MNPT Yellow P N 400162 Hose Assy LP 6 1 4 MNPT Yellow P N 400163 Fitting QD Female 1 4 FNPT P N 400165...

Page 87: ...dprofessional AQUA LUNG G3000SS HELMET OPERATIONS MAINTENANCE MANUAL 2014 Aqua Lung International 2340 Cousteau Court Vista CA 92081 Phone 760 597 5000 Fax 760 597 4900 www aqualung com militaryandpro...

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