Aqua Lung G3000SS Manual

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

2 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual
COPYRIGHT NOTICE
This manual is copyrighted, all rights reserved. It may not, in whole or in part, be copied, photocopied,
reproduced, translated, or reduced to any electronic medium or machine readable form without prior
consent in writing from 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.
© 2018 AQUA LUNG AMERICA, INC.
AQUA LUNG G3000SS DIVING HELMET OPERATIONS & MAINTENANCE MANUAL, PN 400179
Aqua Lung G3000SS Diving Helmet
PN 400300 Helmet Complete, G3000SS
PN 400301 Helmet Complete, G3000SS w/ Hi - Use Connector
PN 400302 Helmet Complete, G3000SS w/ Marsh Marine Connector
You can contact a Technical Advisor via e-mail at:
[email protected]
[email protected]
[email protected]
Warnings, Cautions and Notes:
Pay special attention to information provided in warnings, cautions and notes which are accompanied
by these symbols:
A NOTE is used to emphasize important points, tips, and reminders.
A CAUTION indicates any situation or technique that could cause damage
to the product, and could subsequently result in injury to the user.
AWARNING indicates a procedure or situation that if not avoided,
could result in serious injury or death to the user.

3
TABLE OF CONTENTS
I. SAFETY INFORMATION ....................................................................................................................................................6
Operator and Technician Training ................................................................................................................................6
Recommended Air Supply Pressure ............................................................................................................................6
Long Duration & Cold Water Diving .............................................................................................................................6
II. WARRANTY INFORMATION.............................................................................................................................................6
OPERATIONS SECTION
III. HELMET OPERATING INFORMATION ...........................................................................................................................7
Helmet Description ........................................................................................................................................................7
Performance & Certication .........................................................................................................................................7
Dive System Requirements...........................................................................................................................................8
Bailout Congurations ..................................................................................................................................................9
Helmet Set-Up Procedures.......................................................................................................................................... 11
User Checklists ............................................................................................................................................................ 11
Gas Supply Pressures................................................................................................................................................. 11
Gas Specications....................................................................................................................................................... 11
Suit Ination ................................................................................................................................................................. 11
Use with Low Pressure Oxygen .................................................................................................................................12
Noise Exposure............................................................................................................................................................12
Helmet Weight and Mass.............................................................................................................................................12
Head Protection ...........................................................................................................................................................12
Environmental Conditions ..........................................................................................................................................12
G2000SS Helmet Conversion......................................................................................................................................12
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. HELMET TECHNICAL INFORMATION...........................................................................................................................26
Authorized Technicians...............................................................................................................................................26
Factory Prescribed Procedures..................................................................................................................................26
Scheduled Service .......................................................................................................................................................26
Lubrication ...................................................................................................................................................................26
Technician Checklists..................................................................................................................................................27
General Guidelines ......................................................................................................................................................27

4 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual
VI. STEP-BY-STEP DISASSEMBLY / ASSEMBLY INSTRUCTIONS .................................................................................28
Notes on Disassembly and Reassembly ...................................................................................................................28
Helmet Sub-Assemblies in this Section ....................................................................................................................28
Tools Required for Annual Maintenance ...................................................................................................................28
G3000SS Diving Helmet Disassembly Procedures...................................................................................................29
Neck Dam and Quad Ring.....................................................................................................................................29
Neck Retainer and Locking System.....................................................................................................................29
Head Liner ..............................................................................................................................................................30
Nose Clearing Device (NCD).................................................................................................................................31
Oral - Nasal Mask...................................................................................................................................................31
Communications ...................................................................................................................................................32
Double Exhaust / Water Dump Valve ...................................................................................................................33
Manifold..................................................................................................................................................................34
Airway.....................................................................................................................................................................35
Second Stage Regulator .......................................................................................................................................35
Defogger.................................................................................................................................................................36
Free Flow / Water Dump Valve..............................................................................................................................36
Face Port ................................................................................................................................................................38
G3000SS Diving Helmet Reassembly Procedures....................................................................................................39
Face Port ................................................................................................................................................................39
Free Flow / Water Dump Valve..............................................................................................................................40
Airway.....................................................................................................................................................................41
Manifold..................................................................................................................................................................41
Double Exhaust / Water Dump Valve ...................................................................................................................42
Defogger.................................................................................................................................................................44
Second Stage Regulator .......................................................................................................................................44
Nose Clearing Device (NCD).................................................................................................................................44
Oral - Nasal Mask...................................................................................................................................................45
Communications ...................................................................................................................................................45
Head Liner ..............................................................................................................................................................46
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
Part 3 - Helmet Final Testing ................................................................................................................................69

5
VIII. APPENDICES............................................................................................................................................................... 72
A. Main Assemblies ..................................................................................................................................................... 73
B. Inner Components................................................................................................................................................... 74
C. Manifold.................................................................................................................................................................... 75
D. Free Flow / Water Dump Valve ............................................................................................................................... 76
E. Second Stage Regulator ......................................................................................................................................... 77
F. Nose Clearing Device (NCD) ................................................................................................................................... 78
G. Neck Dam................................................................................................................................................................. 79
H. Welding Shield Kit................................................................................................................................................... 80
I. Welding Shield Assembly Installation Instructions............................................................................................... 81
J. Free Flow Plug Insert Kit Installation Instructions ............................................................................................... 82
K. Camera / Light Bracket Installation Instructions.................................................................................................. 84
L. Terminal Block Communications Kits ................................................................................................................... 85
M. Twist-On Communications Kits............................................................................................................................. 86
N. Communications Kit Installation Instructions...................................................................................................... 87
O. Torque Specications............................................................................................................................................. 91
P. Recommended Cleaners and Lubricants .............................................................................................................. 92
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

6 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual
I. SAFETY INFORMATION
OPERATOR AND TECHNICIAN TRAINING
The G3000SS Diving Helmet should be used and operated by properly trained and certied
divers and tenders only.
The technical procedures in this manual are to be performed only by personnel who have
received factory authorized training through an Aqua Lung Service & Repair Seminar.
RECOMMENDED AIR SUPPLY PRESSURE
The recommended air supply pressure is 129 - 326 PSI (8.9 - 22.5 BAR) Over Bottom Pressure as per
the G3000SS Diving Helmet Regulated Supply Pressure Table in Checklist 3, In-Water Checklist for
Supervisor.
LONG DURATION & COLD WATER DIVING
Diving for long durations and/or in cold water may subject the diver to severe body and respiratory heat
loss. This may lead to a decrease in body core temperature also known as “hypothermia.” Hypothermia
is an extremely dangerous 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 helmet to be free from defects in workmanship for a period of
twelve (12) months from date of purchase.
Parts covered under the warranty:
• This warranty covers all metal parts.
Parts not covered under the warranty:
• This warranty does not cover any soft parts (e.g. o-rings, diaphragms), communications
components, headliners, or chrome plating. Due to the electrolytic nature of underwater cutting
and welding, chrome plating cannot be warranted when the diver engages in these activities.
The warranty becomes null and void if:
• The product has been modied 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.

7
III. HELMET OPERATING INFORMATION
HELMET DESCRIPTION
The G3000SS Diving Helmet is a high performance diving helmet for professional diving applications.
The key features of the G3000SS include:
• Balanced design second stage regulator manufactured by Apeks.
• High grade communications manufactured by OTS.
• Stainless steel (316L) shell, neck retainer and neck ring: no dissimilar metals.
• Breathing loop components protected inside shell.
• Low component count and reduced maintenance load.
• Optional modication kit for eld conversion to free ow mode.
OPERATIONS SECTION
The G3000SS has a similar design to the original Gorski G2000SS helmet but with these upgrades:
• Apeks GX300 second stage regulator.
• Double exhaust and double water dump protection.
• Ergonomic free ow knob.
• 4-wire communications (Marsh Marine or Hi-Use version).
PERFORMANCE AND CERTIFICATION
The G3000SS Diving Helmet:
• Is suitable for use with standard compressed breathing air ("diving air"). See below.
• Meets Work of Breathing (WOB) performance requirements at all required standard and high
Respiratory Minute Volume (RMV) work rates.
• Meets inspired partial pressure of carbon dioxide performance requirements at all required
standard and high Respiratory Minute Volume (RMV) work rates.
• Is tested and certified for use in water temperatures down to 4 degrees Celsius (39.2
degrees Fahrenheit).
The G3000SS Diving Helmet has been CE certied by DNV-GL, Det Norske Veritas-Germanischer Lloyd
SE, Brooktorkai 18, 20457 Hamburg, Germany, Notied Body number 0098 and has been found to be in
accordance with the requirements of EC Directive 89/686/EEC for Personal Protective Equipment (PPE).
When examined the product satised the requirements of the manufacturer’s technical specications
(based upon EN 15333-1: 2008, Respiratory Equipment – Open-circuit umbilical supplied compressed
gas diving apparatus requirements), which has been previously assessed and deemed to meet the
basic health and safety requirements (Annex II) of the directive. The DNV GL Certicate Nos are
55594-14 HH, and 55594-14 HH Addition 1.
The CE certication for the G3000SS Diving Helmet includes the use of the Bailout Switch Block and
the Helmet Side Block. See Bailout Conguration section below for further information.
CE certication of the Emergency Gas Supply (EGS) or bailout system includes the mandatory use of
Apeks rst stage regulators type FSR (XTX200), FST (XTX100), DST (XTX50), or DST.
The CE certicated depth of 50 m (165 ft) is a standard maximum certication depth for diving equipment that
is used to provide a uniform benchmark for measuring performance. It is not an equipment depth limitation.

8 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.
• Emergency Gas Supply (EGS) or bailout gas supply (including rst stage regulator tted with
pressure gauge, and pressure relief valve). All EGS components are to be CE-certied.
• Diving Harness (for attachment of umbilical, bailout gas supply and weights).
• Personal diving equipment (e.g. suit, ns, gloves).
Diver dressed in Aqua Lung (Gorski) G3000SS Diving Helmet with
harness mounted Bailout Switch Block (bailout conguration 1).
Diver wearing Aqua Lung H3 Diving Harness and HAZMAT dry suit.

9
BAILOUT CONFIGURATIONS
All Emergency Gas Supply (EGS) or bailout supply congurations use a diving cylinder and rst stage
regulator tted with a submersible pressure gauge (SPG) and an adjustable pressure relief valve (AP0849/K).
WARNING: The EGS/Bailout supply rst stage regulator must be tted with a pressure
relief valve in a Medium Pressure (MP) port. This is to protect the MP hose in the event
of rst stage regulator malfunction.
CAUTION: The EGS/Bailout Cylinder may be rigged in a “Valve Up” or “Valve Down’ position
in Bailout Congurations 1 and 2. Users must be aware of the potential for obstruction of
the helmet manifold if the bailout system is rigged in the cylinder "Valve Up" conguration.
Bailout Conguration 2 - EGS/Bailout Cylinder with Helmet Side Block.
This conguration uses a Helmet Side Block P/N AP0281/SB mounted on the right hand side of
the helmet. The helmet side block provides an easy to operate ON/OFF valve for the EGS/bailout
supply. The bailout inlet connections on the helmet and the side block are standard 9/16 inch
SCUBA male ttings.
Reference: Apeks document no. 530009, Helmet Side Block Valve Owner & Maintenance Manual.
In both congurations the bailout supply is routed from the EGS/bailout cylinder (tted with rst stage
regulator) rst through the switch block or helmet side block then to the helmet manifold. The EGS/
bailout cylinder is opened during pre-dive checks and remains open throughout the dive. The switch
block or helmet side block is opened during pre-dive checks and then remains closed until required for
use. All hoses remain pressurized to prevent water ingress (See bailout conguration photos 1 & 2
on the next page).
There are 2 standard congurations for an Emergency Gas Supply (EGS) or bailout supply:
Bailout Conguration 1 - EGS/Bailout Cylinder with harness-mounted Switch Block.
This conguration uses a Bailout Switch Block P/N AP0281/G mounted on the diver’s harness. The
switch block provides an easy to operate ON/OFF valve for the EGS/bailout supply. The bailout
inlet connections on the helmet and the switch block are standard 9/16 inch SCUBA male ttings.
Reference: Apeks document no. AP2549, Switch Block Valve Owner & Maintenance Manual.
In addition there is a third, alternative, equipment conguration for use with an Emergency Gas Supply
(EGS) or bailout supply:
Bailout Conguration 3 - EGS/Bailout Cylinder with direct connection to helmet.
This conguration uses the cylinder “Valve Down” conguration with the bailout supply hose
connected directly from the bailout rst stage regulator to the rear manifold on the helmet. During
pre-dive checks the bailout rst stage regulator and hose are pressurized and the cylinder valve
is then closed. The pressurized hose prevents water ingress. Opening the bailout cylinder valve
provides bailout gas directly to the helmet. In this case the diver must be able to operate the cylinder
valve within 10 seconds. This is known as the Direct Bailout Conguration.

10 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual
Upper hose routed from harness-mounted
switch block to helmet manifold.
Bailout Conguration 1
EGS / Bailout Cylinder with Harness-Mounted Switch Block
Bailout Conguration 2
EGS / Bailout Cylinder with Helmet Side Block
Upper hose routed from EGS / Bailout
cylinder to helmet side block, lower hose
routed to helmet manifold.
Lower hose routed from EGS / bailout cylinder
to harness-mounted switch block.