Aqua Lung G3000ss Helmet Operations & Maintenance Manual

AQUA LUNG G3000SS HELMET OPERATIONS & MAINTENANCE MANUAL

Rev. 7/16 2 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

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.

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]

Trademark Notice Aqua Lung®, is a registered trademark of Aqua Lung America, Inc.

Warnings, Cautions and Notes: Pay special attention to information provided in warnings, cautions, and notes, that is accompanied by these symbols:

A WARNING indicates a procedure or situation that if not avoided, could result in serious injury or death to the user.

A CAUTION indicates any situation or technique that could cause damage to the product, and could subsequently result in injury to the user.

A NOTE is used to emphasize important points, tips, and reminders. 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 & Certification ��7 Dive System Requirements ��8 Bailout Configurations ��9 Helmet Set-Up Procedures �� 11 User Checklists ��11 Gas Supply Pressures �� 11 Gas Specifications ��11 Suit Inflation ��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 Specifications �� 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 certified 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 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. 7

OPERATIONS SECTION 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 modification kit for field conversion to free flow mode. 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 flow 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 certified by DNV-GL, Det Norske Veritas-Germanischer Lloyd SE, Brooktorkai 18, 20457 Hamburg, Germany, Notified 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 satisfied the requirements of the manufacturer’s technical specifications (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 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 Configurationsection below for further information. CE certification of the Emergency Gas Supply (EGS) or bailout system includes the mandatory use of Apeks first stage regulators type FSR (XTX200), FST (XTX100), DST (XTX50), or DST. The CE certificated depth of 50 m (165 ft) is a standard maximum certification 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 first stage regulator fitted with pressure gauge, and pressure relief valve). All EGS components are to be CE-certified. • Diving Harness (for attachment of umbilical, bailout gas supply and weights). • Personal diving equipment (e.g. suit, fins, gloves).

Diver dressed in Aqua Lung (Gorski) G3000SS Diving Helmet with harness mounted Bailout Switch Block (bailout configuration 1). Diver wearing Aqua Lung H3 Diving Harness and HAZMAT dry suit. 9

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. This is to protect the MP hose in the event of first stage regulator malfunction.

There are 2 standard configurations for an Emergency Gas Supply (EGS) or bailout supply:

Bailout Configuration 1 - EGS/Bailout Cylinder with harness-mounted Switch Block. This configuration 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 fittings. Reference: Apeks document no. AP2549, Switch Block Valve Owner & Maintenance Manual.

Bailout Configuration 2 - EGS/Bailout Cylinder with Helmet Side Block. This configuration 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 fittings. Reference: Apeks document no. 530009, Helmet Side Block Valve Owner & Maintenance Manual.

In both configurations the bailout supply is routed from the EGS/bailout cylinder (fitted with first stage regulator) first 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 configuration photos 1 & 2 on the next page).

CAUTION: The EGS/Bailout Cylinder may be rigged in a “Valve Up” or “Valve Down’ position in Bailout Configurations 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" configuration.

In addition there is a third, alternative, equipment configuration for use with an Emergency Gas Supply (EGS) or bailout supply: Bailout Configuration 3 - EGS/Bailout Cylinder with direct connection to helmet. This configuration uses the cylinder “Valve Down” configuration with the bailout supply hose connected directly from the bailout first stage regulator to the rear manifold on the helmet. During pre-dive checks the bailout first 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 Configuration. 10 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

Bailout Configuration 1 EGS / Bailout Cylinder with Harness-Mounted Switch Block

Lower hose routed from EGS / bailout cylinder Upper hose routed from harness-mounted to harness-mounted switch block. switch block to helmet manifold.

Bailout Configuration 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. 11

HELMET SET-UP PROCEDURES The following 2 functional checks are essential and are to be conducted prior to diving. Check Valves: The helmet is equipped with two check valves, one for the main gas supply and the other for the Emergency Gas Supply (bailout). Each check valve should be checked prior to connecting a gas hose. To check each check valve, the free flow valve must be open and the tender or diver must try to pull (inhale) breathing gas through the check valve to verify that it is closed. The umbilical gas hose may be attached only after verifying that the check valves are functioning properly. The procedure for testing the check valves is detailed in the Daily Checklist (See Checklist 1 for details). Emergency Gas Supply (EGS) Functional Check: After the diver has verified a proper seal of the helmet on his head and the main breathing gas supply is bled from the gas hose, the diver must test his Emergency Gas Supply (bailout). The procedure for testing the bailout supply is detailed in the Pre- Dive Checklist (See Checklist 2 for details).

USER CHECKLISTS The following checklists are provided to assist all users: • Checklist 1 - Daily Checklist ...... Section IV • Checklist 2 - Pre-Dive Checklist ...... Section IV • Checklist 3 - In-Water Checklist ...... Section IV • Checklist 4 - Post-Dive Checklist ...... Section IV

GAS SUPPLY PRESSURES 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. The regulated surface supply pressures are intended for use with properly adjusted and maintained G3000SS helmets only. They should not be used with other manufacturers’ helmets or masks. The G3000SS helmet and the umbilical and associated supply system must be properly configured, maintained, and adjusted in order to supply the diver with the correct quantity of breathing gas.

GAS SPECIFICATIONS Compressed breathing air used with the G3000SS Diving Helmet must be in accordance with EN 12021: 2014, Respiratory equipment. Compressed gases for breathing apparatus.

SUIT INFLATION Suit inflation systems must only use air or gas mixtures with an oxygen content less than or equal to that in air as specified in EN 12021. A Flow Restrictor (AP0730) should always be fitted whenever a suit inflator hose is fitted to the MP outlet port on the helmet manifold. This in-line flow restrictor will reduce gas flow, and consequential loss of breathing gas, in the event of a suit inflation hose failure. 12 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

USE WITH LOW PRESSURE OXYGEN All breathing loop materials are compatible for use with low pressure pure oxygen (100% O2) at pressures up to 25 bar (363 psi). See Appendix P for guidance on suitable lubricants. NOISE EXPOSURE The maximum internal noise levels for the G3000SS diving helmet are as 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 calculated using the above levels, the applicable national occupational health limits, and the expected time that the diver will spend at each 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.

ENVIRONMENTAL CONDITIONS The G3000SS is suitable for diving in all common environmental conditions with the following guidance: Contaminated Water Diving (CWD): Diving in contaminated waters requires special training, equipment, and procedures for all personnel involved. All helmets and suits may leak water under certain conditions. The G3000SS has a double exhaust regulator and double exhaust / water dump exhaust fitted as standard in order to provide an increased level of protection for the diver. The G3000SS diving helmet is suitable for diving in contaminated water in accordance with national and international regulations and safety codes. Decompression diving: This type of 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.

G2000SS HELMET CONVERSION Existing Gorski G2000SS diving helmets may be converted to the G3000SS diving helmet standard by retrofit of the items listed below. A double exhaust / water dump must be fitted at the same time to ensure that the helmet provides a dual valve (i.e. double exhaust) level of protection. See Appendix A for details of the double water dump exhaust. The following items are needed to convert a G2000SS to a G3000SS diving helmet: • PN AP0300, Apeks GX300 Regulator • PN AP0270, Handwheel Assembly • PN 400111, Double Exhaust / Water Dump Kit • PN 400150 Terminal Block Hi-Use Communications Module Kit or 400151 Terminal Block Marsh • Marine Communications Module Kit. • PN 400017, Communications Bulkhead • Upgraded Latch Catch Assemblies and Neck retainer - See Appendix A 13

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” and “hook & loop” are used throughout this manual. Hook & Loop is commonly known as Velcro®, which is a trademarked brand of hook & loop. Some of the helmet components have hook & loop attachments, including the head liner, free flow plug kit and microphone. 14 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

CHECKLIST 1 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.

WARNING: Aqua Lung strongly recommends 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 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 correctly maintained and serviceable Emergency Gas Supply (EGS) must be used. The EGS must include a 1st stage regulator fitted with submersible pressure gauge and pressure relief valve. The EGS must be confirmed as fully functional prior to diving.

NOTE: When using the EGS, during completion of the daily checklist, the first stage regulator must have an intermediate pressure (IP) output set between 129 and 150 psig (8.9 - 10.3 BAR). In addition, the first stage regulator bleed/pressure relief valve should be set between 180 and 200 psig (12.4 - 13.8 BAR).

COMPLETE THE FOLLOWING BOXES PRIOR TO THE CHECKLIST

COMPLETE THE SIGNATURE, DATE AND COMMENTS AT THE END OF THE CHECKLIST

Helmet Serial No: Date:

Diver / Tender: (Print Name) 15

DAILY CHECKLIST (continued) ACTION PROCEDURE INITIALS NECK RETAINER AND • Visually inspect the neck retainer assembly for LOCKING SYSTEM signs of damage, such as bends. Confirm that (must be completed by diver/tender) the retainer fits properly. • Make sure the locking system (both L and R) is properly working and not deformed in any way. NECK DAM • Visually inspect the neck dam ring for signs of (must be completed by diver/tender) damage, such as bends, scratches on the o-ring surface area or any other deformities. • Visually inspect the neck seal for signs of damage such as tears, rips or cuts. • If the quad ring is dry, lightly lubricate the quad ring. • Replace the neck dam assembly onto the helmet and ensure a proper fit.

HELMET INSPECTION • Visually inspect the helmet (interior and exterior) (must be completed by diver/tender) for damage and/or contamination. NOTE: 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 installed correctly and that the oral-nasal mask is installed on the regulator. • Check that the nose clearing device operates without problems. If necessary lubricate o-rings and stem (Refer nose clearing device assembly section of the operations and maintenance manual for guidance). • Ensure the speakers and microphones are properly installed. Refer to the communications assembly section of the operations and maintenance manual for guidance. • Ensure that the head liner fits properly andis secured to the inside of the helmet shell. Check for worn-off hook and loop, tears and/or rips. (Refer to the head liner assembly section of the operations and maintenance manual for guidance).

NOTE: The head liner should be fitted carefully into the helmet shell so that visible parts of the helmet shell (i.e. bare spots) are minimized. 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 (must be completed by diver/tender) damage or defect. • Ensure that the bailout cylinder is within the VIP and the hydrostatic date. NOTE: Ensure that the EGS • Check the first stage regulator intermediate is maintained properly. pressure (IP) setting before each dive. • Make sure there is no damage to the diver harness and cylinder retention straps. Repair or replace if damaged. • Visually inspect the bailout switch block or helmet side block (if fitted) for any signs of damage or defect, and confirm that it is attached securely to the diver harness. CONNECT THE EGS TO • Confirm the check valve is properly functioning by THE HELMET orally checking it (suck on valve to confirm seal). (must be completed by diver/tender) • Connect the first stage regulator, fitted with submersible pressure gauge, to the EGS cylinder then proceed as follows: DIRECT BAILOUT CONFIGURATION: Connect the regulator hose directly to the helmet check valve. BAILOUT SWITCH BLOCK OR HELMET SIDE BLOCK CONFIGURATION: Connect the regulator hose to the bailout inlet connection on the switch block or helmet side block. Connect the second hose from the switch block or helmet side block outlet to the helmet check valve. • With the cylinder supply turned off, open and close the free flow / water dump valve to verify efficient operation of the valve. • Open the EGS supply valve on the cylinder and log the pressure. EGS CYLINDER PRESSURE ______psig. • Immediately after logging the EGS cylinder pressure, proceed as follows: DIRECT BAILOUT CONFIGURATION: Open the helmet free flow / water dump valve ¾ to 1 full turn and confirm a powerful flow of gas coming out of the defogger train. BAILOUT SWITCH BLOCK OR HELMET SIDE BLOCK CONFIGURATION: Open the switch block or helmet side block valve prior to opening the helmet free flow / water dump valve and confirming the gas flow. • After confirmation, close the free flow / water dumpvalve (and switch block or helmet side block valve if fitted). 17

DAILY CHECKLIST (continued) ACTION PROCEDURE INITIALS

ATTACH THE UMBILICAL • Confirm the check valve is properly functioning by (to be completed by tender) orally checking it (suck on valve to confirm seal). • Blow air through the umbilical to remove any debris, and attach the umbilical into the umbilical adapter located on the check valve.

CHECK THE SECOND • Slowly depress the purge button to full extent and STAGE REGULATOR confirm a sufficient audible flow of gas. (must be completed by diver/tender) NOTE: If the regulator free flows, or if after fully depressing the purge button there is a weak flow of gas, the regulator needs to be adjusted or the low pressure valve should be replaced or serviced by a trained technician. CONFIRM FUNCTION OF • Check all communications to confirm correct COMMUNICATIONS functioning. (to be completed by diver) CHECK DRY-SUIT • If fitted, confirm the dry suit inflation valve and INFLATION HOSE exhaust valve are functioning properly. (must be completed by tender). CHECK HELMET FOR • Apply soap and water to ALL gas fittings and LEAKS connections (including the EGS) to check for leaks on the helmet. FINAL CHECK • Check to ensure the neck retainer is in the correct (to be completed by tender) position and properly locked. • Ensure the diver's safety harness is in good condition. • Check for free movement of the helmet. • Ensure the EGS hose quick disconnect is in good condition and is functioning properly. • Ensure diver has boots, gloves, knife and other accessories.

Signature: Date:

To Diver / Tender: Note comment on the space provided below. Be sure to log maintenance in the applicable maintenance log. Comments: 18 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

CHECKLIST 2 G3000SS DIVING HELMET PRE-DIVE CHECKLIST

BEFORE COMPLETING THIS CHECKLIST, THE DAILY CHECKLIST MUST BE COMPLETED. BEFORE DIVING THE G3000SS DIVING HELMET, THE PROCEDURES IN THIS CHECKLIST MUST BE COMPLETED.

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.

COMPLETE THE FOLLOWING BOXES PRIOR TO THE CHECKLIST

COMPLETE THE SIGNATURE, DATE AND COMMENTS AT THE END OF THE CHECKLIST

Helmet Serial No: Date:

Diver/Tender: (Print Name) 19

PRE-DIVE CHECKLIST (continued) ACTION PROCEDURE INITIALS SUPPLY GAS • Supervisor must ensure the diver has sufficient (must be completed by supervisor) breathing gas pressure supplied to the helmet for depth. BREATHING SYSTEM • Ensure proper functioning of free flow valve by FUNCTION CHECK opening and closing the valve. (must be completed by diver) • Check that breathing resistance is comfortable. • Ensure gas purge function by pressing in the purge button. • Ensure the bail out cylinder valve is closed.

COMMUNICATION CHECK • Ensure the speakers and microphone are (must be completed by diver functioning correctly. and communications operator) CHECK DRY SUIT • Ensure dry suit inflation valve and exhaust valve INFLATION HOSE are functioning correctly. (must be completed by tender) FULL HELMET CHECK • Check all helmet gas fittings and connections for (must be checked by supervisor) leaks. Check EGS for leaks. • Check adjustment or fit of entire helmet, including the divers safety harness, free movement of the helmet, EGS hose quick disconnect, boots, gloves, knife and accessories. EGS FUNCTIONAL • Turn off the main breathing gas supply and CHECK breathe down the umbilical (free flow / exhaust (must be completed by diver valve may be used to assist). and witnessed by tender) • Open EGS (bailout) supply (i.e. cylinder valve, or cylinder valve and switch block or helmet side block valve, depending on bailout configuration) and take two breaths from the EGS supply. • Close the EGS supply valve(s) as follows: DIRECT BAILOUT CONFIGURATION: Close the cylinder valve (the hose remains pressurized). BAILOUT SWITCH BLOCK OR HELMET SIDE BLOCK CONFIGURATION: Close the switch block or helmet side block valve. The cylinder valve is to remain open. Both hoses remain pressurized. • Open main breathing gas supply. Diver reports: Breathing OK. NOTE: This check is mandatory and must be completed for all EGS (bailout) configurations. After checking, the EGS supply must be shut leaving the supply hose(s) pressurized. 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 RIG points: (must be completed by supervisor) • Head liner secured inside the helmet shell. • Neck dam is installed. WARNING: Both latch • Neck retainer secured with both locking catches catches must fit into (L and R) engaged on neck retainer. place correctly or the helmet may flood. • Chin strap properly fastened. • Check adjustment and fit of the diver's safety harness, free movement of the helmet, EGS hose quick disconnect, boots, gloves, etc. • Ensure helmet supply pressure is at minimum 129 psig (8.9 bar) as per the regulated supply pressure table in Checklist 3, In-Water Checklist for Supervisor.

FINAL BREATHING • Check to ensure the helmet is breathing correctly CHECK with no complications. (must be completed by diver) NOTE: Ensure all equipment is properly adjusted and is properly functioning.

Signature: Date:

Comments: 21

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: When diver uses less than the minimum recommended supply pressure, the work must be adapted to prevent over-breathing the system, which will result in exhaustion.

COMPLETE THE FOLLOWING BOXES PRIOR TO THE CHECKLIST

COMPLETE THE SIGNATURE, DATE AND COMMENTS AT THE END OF THE CHECKLIST

Helmet Serial No: Date:

Diver/Tender: (Print Name)

PROCEDURE INITIALS 1. The diver must ensure the helmet is breathing and must report that breathing is satisfactory.

2. The diver must ensure the helmet is watertight and if wearing a dry-suit, the diver must ensure no leakage occurs. Diver must report that a proper seal has been made. 22 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

IN-WATER CHECKLIST (continued)

G3000SS DIVING HELMET 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.

NOTE: The supply pressures listed in the table below were derived by breathing simulator trials for optimum performance at each depth using a breathing rate which simulates hard work (an RMV of 62.5 lpm). They were obtained using a 100 meter [328 ft] umbilical with a minimum I.D. of 9.5mm [0.375”] with not more than two sections. Use of different size umbilicals will affect performance.

Depth Recommended Supply Pressure Range

(MSW) (FSW) (BAR) (PSIG)

MINIMUM MAXIMUM MINIMUM MAXIMUM

00-20 00-66 8.9 10.9 129.0 158.0

21-30 69-98 11.0 12.4 160.0 180.0

31-40 102-131 13.3 15.4 193.0 223.0

41-50 135-164 17.5 20.5 254.0 297.0

51-60 (not recommended 167-197 (not recommended when using compressed air) when using compressed air) 21.5 22.5 312.0 326.0

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. The HP gas supply system will automatically adjust the diver’s gas supply pressure with changes in depth. Always refer to the manufacturer’s instructions for the system being used.

Signature: Date:

Comments: 23

CHECKLIST 4 G3000SS DIVING HELMET POST-DIVE CHECKLIST

THE POST-DIVE CHECKLIST MUST BE COMPLETED AT LEAST ONCE A DAY WHEN DIVING 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.

COMPLETE THE FOLLOWING BOXES PRIOR TO THE CHECKLIST

COMPLETE THE SIGNATURE, DATE AND COMMENTS AT THE END OF THE CHECKLIST

Helmet Serial No: Date:

Diver/Tender: (Print Name) 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.

3. Wash the outside of the helmet and all external fittings completely with fresh water. This removes dirt and prevents surface corrosion. If required, wash with soap and water, rinse with fresh water and allow to dry.

4. Visually inspect the helmet fully for damage.

5. Remove the speakers from the headliner.

6. Remove the head liner. Visually inspect for damage and/or deterioration. If the head liner is wet, air dry it.

NOTE: The head liner may be washed as required.

7. If required, and particularly if the inside of the regulator was exposed to salt or contaminated water, remove the regulator and the oral-nasal mask from the helmet. Wash the exhaust assembly carefully with soap and water, rinse thoroughly with fresh water and allow to dry. DO NOT allow water to enter the regulator body. Re-install into helmet upon completion. After diving in extreme conditions (e.g. sand, sediment), or if wet breathing was experienced, proceed as follows (the regulator may remain installed in the helmet): • Remove exhaust valve cover and the complete diaphragm assembly from the regulator. • Rinse the diaphragm assembly and the exposed inside of the regulator with fresh water. • Check the condition and correct installation of both diaphragms. • Dry out and reinstall the diaphragm assembly and the exhalation valve cover.

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. 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.

10. Clean neck dam, neck retainer and latch catches with soap and water, rinse with fresh water and allow to dry.

11. Wipe helmet down to remove 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 soap and water, rinse with fresh water and allow to dry.

13. Any defects or damage found during post-dive procedures must be noted on the front page and brought to the attention of the supervisor and/or helmet technician.

DEFECTS AND DAMAGES: Any defects or damages found during post-dive procedures must be noted and brought to the attention of the supervisor and/or technician.

Signature: Date:

Comments: 26 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

TECHNICAL SECTION V. HELMET TECHNICAL INFORMATION

AUTHORIZED TECHNICIANS

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.

FACTORY PRESCRIBED PROCEDURES

This manual provides factory prescribed procedures for the correct service and repair of the G3000SS diving helmet. 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.

SCHEDULED SERVICE

1. The G3000SS Diving Helmet is subject to annual service regardless of usage. 2. The Annual Inspection and Maintenance Checklist must be followed for annual service. See Checklist 6 for details of annual service. 3. The annual service kit (P/N 400180) contains all parts that are replaced annually (See Appendix R) for details of this kit. 4. A full service consists of the following mandatory procedures: • Disassembly and replacement of specific parts. • Reassembly and lubrication of specific parts. • Helmet final testing.

LUBRICATION

An oxygen compatible lubricant must be used when diving with 100% oxygen or gas containing oxygen percentages greater than 40%. All helmet components requiring lubrication are lubricated with Christo- Lube® MCG 111 during assembly.

All o-rings must be lubricated prior to assembly.

CAUTION: DO NOT lubricate diaphragms or one-way valves. Lubrication attracts dirt and debris, this may cause the item to malfunction. 27

TECHNICIAN CHECKLIST

The following technician checklists are provided to assist all technicians:

• Monthly Inspection & Maintenance Checklist ………………………………………………..Section VII • Annual Inspection & Maintenance Checklist …………………………………………………Section VII

GENERAL GUIDELINES

1. In order to correctly perform the procedures outlined in this manual, it is important to follow each step exactly in the order given. Read over the entire manual to become familiar with all procedures before attempting to service or repair the G3000SS diving helmet. 2. Keep the manual open beside you for reference while performing each procedure. Do not rely on memory. 3. All service and repair should be carried out in a work area specifically set up and equipped for the task. Adequate lighting, cleanliness, and easy access to all required tools are essential for an efficient repair facility. 4. As each unit is disassembled, reusable components should be segregated 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 prevent damage during the cleaning procedure. 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. 6. Do not attempt to reuse mandatory replacement parts under any circumstance, regardless of the amount of use the product has received since it was manufactured or last serviced. 7. When reassembling, it is important to follow every torque specification prescribed in this manual, using a calibrated Newton Meter (Nm) or Inch Pound (in lb) torque wrench. Some parts are made of either brass or composite materials and can be permanently damaged by undue stress. 28 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

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

1. All components must be clean and fully serviceable prior to assembly.

2. All o-rings must be lubricated prior to assembly.

HELMET SUB-ASSEMBLIES IN THIS SECTION

• Neck Dam and Quad Ring • Manifold • Neck Retainer and Locking System • Airway • Head Liner • Second Stage Regulator • Nose Clearing Device (NCD) • Defogger • Oral-Nasal Mask • Free Flow / Water Dump Valve • Communications • Face Port • Double Exhaust / Water Dump Valve

TOOLS REQUIRED FOR ANNUAL MAINTENANCE

3/8" Nut Driver Circlip Pliers 7/16" Nut Driver Phillips #3 Screwdriver and Screwdriver Bit 3/16" Allen / Hex Key and Hex Bit Socket (Torque) 15/16" Deep Socket and Driver or Wrench 1/4" Allen / Hex Key and Hex Bit Socket (Torque) 11/16" Deep Socket and Driver 5/32" Allen / Hex Key and Hex Bit Socket (Torque) 7/8" Deep Socket and Driver 5/8" Flat OE Low Profile / Slim Wrench 5/8" Crowfoot and 3/8" Extension 11/16" Flat OE Low Profile / Slim Wrench Torque Screwdriver (20 - 140 inch pounds) O-Ring Tool (Brass or plastic) Torque Wrench (10 - 40 foot pounds) 3/8" Flat Blade Screwdriver Soft Jaw Bench Vise Diagonal Pliers Additional tools for the Apeks GX300 Second Stage Regulator are listed in the separate Apeks document 1/4" Flat Blade Screwdriver and Screwdriver Bit GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL. 29

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 the upper neck ring (69), inspect lower neck ring (71) and confirm all screws (75) are present and secure. and replace as required. Inspect the screws (72) are present and secure. Inspect the neck seal (70) for damage quad ring groove on upper neck ring and replace as required. for damage. Note: Refer to "Neoprene Neck Seal Replacement" in Part 2- Helmet Reassembly section of Checklist 6.

NECK RETAINER AND LOCKING SYSTEM

4. Using a 7/16" nut driver and 3/16" 5. Inspect the retainer bolt (23) and 6. If required, remove and inspect allen / hex key, unscrew the retainer neck retainer (21) for damage. both latch catch assemblies. Use a nut (22) from the retainer bolt (23). Note: Check the neck retainer to ensure 5/32" allen / hex key to remove latch Remove the retainer bolt and neck it has not been bent or warped. screw (4) and lock washer (5). retainer (21) from the helmet shell (1). Note: There is no requirement to remove latch catch assemblies unless defective. 30 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

NECK RETAINER AND LOCKING SYSTEM (continued)

7. Latch catch assemblies removed 8. Use a 1/4" allen / hex key to remove 9. Remove the latch spring (8) from from helmet. button cap screw (10) and latch spring the latch (2 or 3). Note: The latch catch assemblies washer (9) from the latch (2 or 3). are side specific (left & right). Note: Previous hex screw used a 3/16" allen / hex key.

10. Remove latch (2 or 3) from the 11. Complete latch catch assembly latch base (6 or 7). Repeat process shown disassembled. for other latch catch assembly.

HEAD LINER

12. Remove speakers (30 & 40) from 13. Visually inspect head liner for the pockets in the head liner. Remove deterioration and/or damage. Wash head liner from helmet shell (1). and dry head liner as required. 31

NOSE CLEARING DEVICE (NCD)

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

ORAL - NASAL MASK

17. Remove the microphone (32), 18. Remove and inspect the inhalation 19. All spokes of the inhalation valve followed by the oral-nasal mask valve housing (37) and inhalation valve housing “wagon wheel” must be (39). Inspect the oral-nasal mask (36) from the oral nasal mask (39). present and secure. The inhalation for damage or deterioration. The valve (36) must sit flat and seal on oral-nasal mask may be washed the housing. and disinfected as required. Note: No cuts or holes are permitted in the oral-nasal mask. It is essential that the mask is intact in order to prevent any CO2 build up inside the helmet. 32 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 (29) and both communications posts unscrewing the retaining nuts inside (32), cables and connections. En- (24). The terminal block is held in the helmet with a 3/8” nut driver. sure that all contact surfaces are place inside the helmet by the posts. cleaned thoroughly.

23. Inspect the terminal block (29) for 24. Visually inspect each post (24) for 25. Use a 11/16" wrench to remove the damage. Ensure that contact surfaces insulation cracks or damage. Replace SS blank plug or bulkhead cap (28) are cleaned thoroughly. posts and plastic tubing (85) as required. and comms cable from the comms Note: There is no requirement to bulkhead (26). remove the posts unless damaged.

26. Use your fingers, hold the modified 27. Remove o-ring (25) from the 28. Using diagonal pliers, cut both nut on the inside of the helmet shell (1). comms bulkhead (26). Complete ferrules (27) off the comms cable. Use a 15/16" deep socket and driver or comms bulkhead disassembled. Remove and inspect the bulkhead wrench to remove the comms bulkhead cap (28) from the 4 wire comms (26) from the helmet shell. cable. Check the comms cable contact surfaces, including the pins on the hi-use or marsh marine connector are cleaned thoroughly. CAUTION: Do not damage the comms cable when removing the ferrules. 33

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" low profile wrench to the screwdriver. from the valve stem (60). swivel nut and loosen it just enough to allow the airway assembly (31) to rotate. Note: Do not unscrew the swivel nut all the way, otherwise the airway assembly may bend out of shape during removal.

32. Remove the screws (11) holding 33. Lift the exhaust valve cover 34. Complete double exhaust / water the exhaust valve cover (19) in place (19) off the exhaust port. Remove dump valve shown disassembled. using a #3 Phillips screwdriver. the exhaust valve (18), spacer rings (17), dual exhaust seat (16) and dual exhaust bushing (15).

35. Temporarily install the exhaust 36. Use a 11/16" deep socket and valve cover (19), three spacer rings driver to release tension on the valve (17) and screws (11) onto exhaust bonnet (63). DO NOT remove the port. This will keep the valve body valve bonnet at this time. (55) from moving when loosening the Note: Leave the exhaust valve cover valve bonnet (63). in place, it will be removed later in the Note: Install screws in triangle disassembly procedure. formation. 34 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). from the manifold body (48). Using short (42) manifold hex screws. your fingers, remove the manifold insert (43) from the manifold body. Remove both o-rings (44) from the manifold insert.

40. Secure the manifold body (48) in 41. Secure both check valves (50) in 42. Using a 3/16" allen / hex key, a soft jaw vise. Remove both brass a soft jaw vise. Using a 11/16" deep remove the port plug (49) from the cap fittings (53) from the SCUBA socket and driver, remove the SCUBA manifold body (48). Remove o-ring (52) and hose (51) fittings. Using a (52) and hose (51) fittings from the (35) from the port plug using a plastic 7/8" deep socket and driver, remove check valves. Clean Teflon tape from or brass o-ring tool. both check valves (50). Clean Teflon SCUBA and hose fittings. tape from both check valves.

43. Using a 7/8" deep socket and 44. Use a plastic or brass o-ring tool 45. Complete manifold shown disas- driver, remove the manifold plug (46) to remove the screen (47) from the sembled. from the manifold body (48). Remove manifold body (48). o-ring (25) from the manifold plug using a plastic or brass o-ring tool. 35

AIRWAY

46. Insert a 3/8" flat blade screw driver 47. Unscrew the swivel nut on the 48. Remove the airway assembly between the helmet shell (1) and the airway assembly (31) from the (31) from the helmet shell (1). air block. Use the screwdriver to gently swagelock connector (33) using a push down on the airblock and rotate 11/16" low profile wrench. the airway out of the helmet shell. CAUTION: To avoid bending the airway, do not use excessive force.

49. Insert a 5/8" low profile wrench 50. Unscrew the swagelock connector 51. Remove o-ring (35) from the onto the swagelock connector (33). (31) from the valve body (55). swagelock connector (33).

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. 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.

52. Unscrew the cap head screws using 53. Turn the GX300 regulator 54. GX300 regulator removed from a 5/32" allen / hex key and remove them slightly clockwise, then gently pull regulator port. Proceed as directed from the valve diaphragm housing. En- out to disengage the o-ring seal. in the above manual for the GX300 sure that the oral-nasal mask (39) has Gently remove the regulator from regulator. been removed from the regulator. the regulator port. 36 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. consists of two components, the Note: Do not use excessive force, the Note: Do not use excessive force, the defogger train (38) and the free flow defogger train should slide out easily. free flow barrel should slide out easily. barrel (34).

FREE FLOW / WATER DUMP VALVE

58. Using a #3 Phillips screwdriver, 59. Remove the free flow / water 60. Unscrew the valve bonnet (63) remove the screws (11), spacer rings dump valve assembly from exhaust from the valve body (55). (17) and exhaust valve cover (19) port. from the exhaust port.

61. Remove the valve stem (60) from 62. Remove the o-ring (62) and Teflon 63. Insert a brass or plastic o-ring tool the valve bonnet (63). washer (61) from the valve stem (60). into the valve body (55) and remove Note: If the o-ring and Teflon washer both copper washers (59). are not on the valve stem, check inside the valve bonnet. 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). from the valve body (55).

67. Remove the exhaust valve (18) 68. Remove both o-rings (54 & 56) 69. Complete free flow / water dump from the valve body (55). from the valve body (55). valve shown disassembled. 38 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). the helmet shell (1). retainer port (12).

73. Use a brass or plastic o-ring tool to 74. Complete face port shown remove o-ring (14) from the groove in disassembled. the face port on the helmet shell (1).

NOTE: Before beginning reassembly, perform parts cleaning and lubrication in accordance with Appendix Q: Cleaning and Lubricating

DISASSEMBLY OF THE G3000SS DIVING HELMET IS NOW COMPLETE 39

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). face port (13) with the beveled edge (14). Install o-ring into the groove Note: If needed, clean the face port on the bottom, facing the helmet. on the helmet shell (1). with soapy water prior to installation. Note: Lubricate the face port o-ring sparingly, i.e. a small amount of Christo-Lube® MCG 111 only.

4. Insert the screws (11) through the 5. Using a #3 Phillips screwdriver port retainer (12) and into the helmet bit and inch pound torque wrench, shell (1). Hand tighten the screws torque each screw (11) to a value of with a #3 Phillips screwdriver. 45 in lb (5 Nm). Note: If any resistance is felt, stop and start over to ensure cross threading is not occurring. 40 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). the valve body (55). the valve snap ring (57) flat side up Note: The orientation of the exhaust into the groove on the valve body (55). valve is critical. The side with the center Note: The flat sideis indicated on the ridge faces up. The exhaust valve must inside radius of the valve snap ring. lay flat against the valve body.

9. Apply a small amount of Christo- 10. Using the valve stem (60) screw 11. Insert two copper washers (59) Lube® MCG 111 to the threads of the the valve seat (58) all the way into the into the valve body (55). If necessary, valve seat (58). valve body (55) until it stops. use a brass or plastic o-ring tool to seat the washer against the bottom of the valve body.

12. Insert the Teflon washer (61), 13. Place the valve stem assembly 14. Place the valve bonnet (63) over followed by the o-ring (62) onto the (60) over the valve seat (58). the valve stem (60) and thread it into valve stem (60). the valve body (55) until hand tight. 41

FREE FLOW / WATER DUMP VALVE (continued)

Notch

15. Install the free flow / water dump 16. Temporarily install the exhaust valve into the helmet shell (1). Align valve cover (19), three spacer rings the swagelock connector opening with (17) and three screws (11) onto ex- the notch on the inside of the helmet. haust port. This will keep the valve Note: The swagelock connector opening body (55) from moving when torquing must be aligned with the notch in order to the valve bonnet (63). install the airway assembly. Note: Install screws in triangle formation. AIRWAY

17. Place o-ring (35) onto the swa- 18. Screw the swivel nut all the way 19. Press inward on the air block to gelock connector (33). Screw the down onto the swagelock connector insert the airway assembly (31) into swagelock connector into the opening (33) until hand tight. Make sure the the helmet shell (1). on the valve body (55) until hand tight. airway assembly can rotate slightly. CAUTION: Do not pinch your Using a 5/8" crowfoot, 3/8" extension Note: Make sure the swivel nut is fingers or hand in between the and inch pound torque wrench, torque threaded all the way down onto the airway assembly and the helmet the swagelock connector to a value of swagelock connector before pressing shell during installation. 45 in lb (5 Nm). the airway assembly into the helmet

MANIFOLD

20. Secure the manifold body (48) in 21. Install o-ring (25) onto the manifold 22. Install o-ring (35) onto the port a soft jaw vise. Insert the screen (47) plug (46). Screw the manifold plug into plug (49). Install the port plug into the into the manifold body, making sure it the manifold body (48) hand tight. Us- manifold body (48) hand tight. Using is aligned with the end of the threads. ing a 7/8" deep socket and inch pound a 3/16" hex / allen key bit and inch torque wrench, torque the manifold pound torque wrench, torque the port plug to a value of 90 in lb (10 Nm). plug to a value of 45 in lb (5 Nm). 42 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). Place the of Teflon tape. Place both check valves into the left manifold port until hand tight. manifold insert through the wall of in a soft jaw vise. Screw the SCUBA and Using a 7/8" deep socket and driver, the helmet shell (1) and into the hose fittings into the check valves until tighten the check valves an additional 1 airway block socket. hand tight. Using a 11/16" deep socket 1/2 turns. and driver, tighten the SCUBA and hose Note: Brass caps (50) will be installed fittings an additional 1 1/2 turns. in the Helmet Final Testing section of this manual.

Long Screw Short Screw 26. Place the manifold gasket (45) 27. Place the manifold body (48) over 28. Use a 3/16" hex / allen bit and driver around the manifold insert (43). Align the manifold insert (43) and align the to install all manifold hex screws. In- the manifold gasket with the screw screw holes. sert the short manifold hex screws (42) holes on the helmet shell (1). through the screw holes and hand tight- Note: Christo-Lube® MCG 111 can be en into the manifold body. Insert the long used to hold the manifold gasket in place. manifold hex screws (41) through the air block and hand tighten into the manifold body. Torque the hex screws to a value of 80 in lb (9 Nm) using an inch pound torque wrench and 3/16" hex / allen bit. DOUBLE EXHAUST / WATER DUMP VALVE

29. Hold the swagelock connector 30. Torque the valve bonnet (63) to a 31. Using a #3 Phillips screwdriver, (33) in place with a 5/8" thin wrench. value of 35 ft lb (5 Nm) using a foot remove the screws (11), spacer rings Using a 11/16" thin wrench, tighten pound torque wrench and 11/16" (17) and exhaust valve cover (19) the swivel nut until it bottoms out on deep socket. from the exhaust port. the swagelock connector. 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). Note: The orientation of the exhaust valve is critical. The side with the center ridge faces up. The exhaust valve must lay flat against the dual exhaust bushing.

35. Place one spacer ring (17) on top of 36. Install remaining spacer rings 37. Place the handwheel knob (20a) the dual exhaust seat (16), followed by (17) and retainer port screws (11) over the valve stem (60). Make sure the exhaust valve cover (19). Align the into the exhaust valve cover (19). to align the square on the knob with screw holes and thread one retainer Once all retainer port screws are the square on the stem to ensure port screw (11) into place using a #3 in place, use a #3 Phillips screw proper function. Phillips screwdriver until hand tight. driver bit and inch pound torque Note: If any resistance is felt, stop and wrench to tighten each screw to start over to ensure cross threading is 45 in lb (5 Nm). not occurring.

38. Insert the spring (20b) into the 39. Place the nut (20c) onto the valve 40. Tighten the nut (20c) onto the free flow knob (20a). stem (60). valve stem (60) using a 3/8" flat blade screwdriver until hand tight. Note: If any resistance is felt, stop and start over to ensure cross threading is not occurring. 44 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

DEFOGGER

41. Slide the free flow barrel (34) over 42. Fit the defogger train (38) onto the the valve body (55). bracket of the free flow barrel (34).

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. 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.

43. Insert the GX300 regulator into the 44. Ensure the valve cover is hand regulator port on the helmet shell (1) tight and the grooves line up with the with the regulator mouthpiece facing screw holes. Install the 3 cap head the bottom of the helmet. Rotate the screws through the valve diaphragm regulator counter-clockwise into place housing and into the helmet shell (1). while gently pushing down to engage Using a 5/32" hex / allen bit and inch the valve spindle onto the free flow / pound torque wrench, tighten the cap water dump valve. head screws to 44 in lb (5 Nm). NOSE CLEARING DEVICE (NCD)

45. Insert the NCD stem (65) through 46. Fold the nose pad (64) over the 47. Install both o-rings (66) onto the the hole in the nose pad (64) and slide metal end of the NCD (65), securing NCD (65). it down to the end (adhesive side first). both sides tightly together with the seam on the bottom. Trim the excess nose pad evenly with scissors. 45

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). Pull on the mask (39) with the inhalation valve (36) (39) with the wires pointed towards stem until the barb passes through facing the inside of the mask. the bottom of the mask. the center hole. Using diagonal pliers, trim the stem 1/4" above the barb. Note: The inhalation valve must be placed on the smaller diameter side of the inhalation valve housing.

51. Place the oral nasal mask (39) 52. Insert the NCD through the small 53. Thread the NCD knob (67) onto the over the regulator mouthpiece. Make round hole in the oral nasal mask end of the NCD (65) until hand tight. sure the end of the mouthpiece is flush (39). Apply Christo-Lube® MCG 111 Note: Do not use any type of thread with the inside of the oral nasal mask. to the two o-rings (66) on the NCD locker on the NCD and knob. (65) and continue to push it out through the helmet shell (1). CAUTION: Be careful not to damage the o-rings during installation of the NCD into the helmet shell.

COMMUNICATIONS

54. Install o-ring (25) into the comms 55. Place flat side of the modified nut 56. Screw the comms bulkhead (26) bulkhead (26). against the airway block inside the into the nut until hand tight. helmet shell (1). 46 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 onto communication posts (24) and the comms bulkhead (26) to 25 ft lb a 11/16" deep socket and inch pound install into the helmet shell (1). (34 Nm). torque wrench to tighten the SS blank plug to 90 in lb (10 Nm).

NOTE: See Appendix N for installation of terminal block, communications kit and wiring instructions. This should be done prior to installing the head liner.

HEAD LINER

Back

Front

60. Cut Velcro into four strips approxi- 61. Attach Velcro strips to the front 62. Correct position of the head liner mately 2 in x 1 in. Clean areas where inside of the helmet shell (1). prior to insertion into helmet shell (1). the Velcro is to be attached with alcohol. Install Velcro strips to the rear inside of the helmet shell (1).

NOTE: If conducting annual maintenance do not install the headliner at this time. The head liner will be installed during Part - 3 Helmet Final Testing section of Checklist 6.

63. Insert the head liner into the 64. Install speakers (30 & 40) into helmet shell (1). the pockets in the head liner. 47

NECK RETAINER AND LOCKING SYSTEM

65. Install latch (2 or 3) into the latch 66. Place the latch spring washer (9) 67. Align the latch catch assembly and base (6 or 7). Place the latch spring onto the button cap screw (10) and latch hole on the helmet shell (1). Place (8) onto the latch. thread it into the latch (2 or 3) until lock washer (5) onto latch screw (4) and Note: The latch catch assemblies hand tight. Use a 5/32" allen / hex key thread into latch catch assembly until are side specific (left & right). bit and inch pound torque wrench to hand tight. Using a 1/4" allen / hex key bit tighten the button cap screw to 80 in lb and inch pound torque wrench tighten the (9 Nm). Repeat process for other latch latch screw to 140 in lb (16 Nm). Repeat catch assembly. process for other latch catch assembly. Note: Previous hex screw (10) used Note: Test the operation of each a 3/16" allen / hex key. latch catch assembly to ensure it can slide, rotate and lock smoothly.

68. Align the neck retainer (21) with the 69. Use a 3/16" allen / hex key to hold the hinge at the rear of the helmet shell (1). In- retainer bolt (23) and 7/16" nut driver to sert the neck retainer bolt (23) and secure hold the retainer nut (22). Tighten until the in place with the neck retainer nut (22). nut touches the hinge. Adjust as required. NECK DAM AND QUAD RING

NOTE: Do not install the neck dam at this time. The neck dam will be installed in the Helmet Final Testing Section of the manual.

70. Install quad ring (68) into the groove 71. Place front of neck dam into helmet 72. With the neck dam in place, ensure on the upper neck ring (69). shell (1). Use the neck retainer (21) to the latch catch assemblies move freely push back of neck dam into place. and lock the neck dam into place. 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. 48 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 49

CHECKLIST 5 G3000SS DIVING HELMET MONTHLY INSPECTION AND MAINTENANCE CHECKLIST

Inspection and maintenance procedures in accordance with this checklist are to be conducted at least once a month for helmets used frequently and once every two months for helmets used less than ten times (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: • The procedures in this checklist are to be performed only by personnel who have received factory authorized training through an Aqua Lung Service and Repair Seminar. • If you do not completely 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 inspection and maintenance is required. • After completing this checklist, it should be kept in the helmet maintenance log/file.

COMPLETE THE FOLLOWING BOXES PRIOR TO THE CHECKLIST

COMPLETE THE SIGNATURE, DATE AND COMMENTS AT THE END OF THE CHECKLIST

Helmet Serial No: Date:

Diver/Tender: (Print Name) 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.

STEPS PROCEDURE INITIALS

NECK DAM • Visually inspect the neck dam ring for signs of damage, such as bends, scratches on the quad ring surface area, or any other deformities. • Visually inspect the neck seal for cuts and /or deterioration. A damaged neck seal must be replaced. • If the quad ring is dry, lightly lubricate the quad ring. • Place the neck dam onto the helmet to make sure it fits properly.

NOTE: Refer to the neck dam and quad ring disassembly section of the operations and maintenance manual for guidance.

NECK RETAINER AND • Visually inspect the neck retainer for damage, LOCKING SYSTEM bends, wear or loose screws. • Confirm correct operation of locking system.

NOTE: Refer to the neck retainer and locking system disassembly section of the operations and maintenance manual for guidance.

HEAD LINER • Visually inspect for deterioration and/or damage. If necessary, replace with new head liner.

NOTE: Refer to the head liner disassembly section of the operations and maintenance manual for guidance. 51

MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued)

STEPS PROCEDURE INITIALS

NOSE CLEARING • Check NCD for ease of movement and then DEVICE (NCD) remove NCD and check for damage to the NCD body and components. • Visually inspect o-rings and neoprene pad for damage and/or deterioration and if necessary replace. Lubricate o-rings lightly as required.

NOTE: Refer to the nose clearing device disassembly section of the operations and maintenance manual for guidance. ORAL-NASAL MASK • Remove oral-nasal mask (remove microphone first) and check for damage (e.g. splits, cuts, tears) and/or deterioration. No damage is permitted.

NOTE: If no damage or deterioration is found, wash oral-nasal mask with soap and water, rinse with fresh water and allow to dry.

NOTE: Refer to the oral-nasal mask disassembly section of the operations and maintenance manual for guidance. INHALATION VALVE • Remove and visually inspect both components HOUSING AND for damage and/or deterioration. DO NOT remove INHALATION VALVE the inhalation valve from the valve housing. (one way valve) NOTE: All spokes of the "wagon wheel" must be present.

NOTE: Refer to the oral-nasal mask disassembly section of the operations and maintenance manual for guidance. 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. • Without removing them, check communication posts and terminal block for insulator cracks or damage. If necessary, replace with new posts.

NOTE: Refer to the communications disassembly section of the operations and maintenance manual for guidance. 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. WARNING: Knob slippage on the stem may cause dangerous conditions to the diver, including death. NOTE: Refer to the double exhaust / water dump valve disassembly section of the operations and maintenance manual for guidance.

DOUBLE EXHAUST / • Remove the five screws, exhaust valve cover, outer exhaust flapper valve, dual exhaust seat WATER DUMP VALVE and dual exhaust bushing. • Visually inspect the outer exhaust flapper valve for damage or deterioration. Wash with soap and water, rinse with fresh water and allow to dry. If necesary, replace exhaust flapper valve. • Clean the external seating surface on the dual exhaust seat (i.e. where the exhaust flapper valve makes contact). NOTE: Refer to the double exhaust / water dump valve disassembly section of the operations and maintenance manual for guidance. FREE FLOW / WATER • Remove the snap ring and inner exhaust flapper valve. DUMP VALVE • Visually inspect the inner exhaust flapper valve for damage or deterioration. Wash with soap and water, rinse with fresh water and allow to dry. If necesary, replace exhaust flapper valve. • Clean the external seating surface on the valve body (i.e. where the exhaust flapper valve makes contact). NOTE: Refer to the free flow / water dump valve disassembly section of the operations and maintenance manual for guidance. MANIFOLD • Without removing the manifold body from the helmet, remove the manifold plug and clean the manifold screen. Refit into manifold body upon completion. • Check both one-way valves for proper operation by sucking on the hose and scuba fittings. NOTE: Refer to the manifold disassembly section of the operations and maintenance manual for guidance. 53

MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS GX300 SECOND STAGE • Remove the GX300 second stage regulator from helmet. REGULATOR • Remove the regulator valve cover and visually inspect the exhaust valve diaphragm assembly for damage or deterioration. Clean components as required. Replace diaphragms if damaged or deteriorated. • Remove the valve spindle assembly from the regulator case. • Visually inspect this assembly, then clean it as required. • Re-set the spindle adjuster to the correct setting (refer to Apeks GX300 Technical Manual). • When dry, re-install valve spindle assembly into the regulator case. • Adjust the lever as required and check regulator adjustment (refer to Apeks GX300 Technical Manual). • Complete the reassembly of the regulator and fit the regulator back into the helmet. 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 • Visually inspect the helmet with the above listed COMPONENTS components removed from the helmet. • Verify condition and inspect for damage to the helmet shell. • Check all o-ring placement surfaces to ensure proper seal. • Wash the shell with soap and water, rinse with fresh water and dry with air and towels. Blow water out of inner airway using compressed air. FINAL ASSEMBLY AND • Refer to the Step-By-Step Reassembly Procedures TEST section to reassemble helmet to original condition. • Refer to the Helmet Final Testing section to perform a functional test and leak check.

Signature: Date: Comments: 54 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual CHECKLIST 6 G3000SS DIVING HELMET ANNUAL INSPECTION AND MAINTENANCE CHECKLIST Inspection and maintenance procedures in accordance with this checklist are to be conducted annually (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.

WARNING: Aqua Lung strongly recommends completion 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 type of activity performed. FAILURE TO COMPLY WITH THIS CHECKLIST MAY RESULT IN SERIOUS INJURY OR EVEN DEATH.

GENERAL INSTRUCTIONS 1. All parts replaced annually are contained in the annual service kit P/N 400180 or P/N 400183 (See Appendix R). These replacement parts are also identified in Appendices A to G. 2. Any damaged or defective parts must be replaced. 3. All parts should be cleaned and lubricated using the standard procedures detailed in Appendix Q. TOOLS REQUIRED FOR ANNUAL MAINTENANCE

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:

Technician: (Print Name)

STEPS PROCEDURE INITIALS

NECK DAM AND QUAD RING NOTE: Refer to the neck dam and quad ring disassembly section of the operations and maintenance manual for guidance.

CHIN STRAP • Visually inspect for tears and cuts. • Replace if damaged or defective. • Check that all screws are present and secure. QUAD RING • Remove and inspect for cuts 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 necessary, replace the neck seal.

UPPER NECK RING • Visually inspect the o-ring groove for damage.

BOTTOM NECK RING • Visually inspect for damage. Check that all screws are present and secure. 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.

LATCH CATCHES • If required, disassemble both (L and R) latch catch assemblies. • Inspect all components for damage. • Clean, reassemble and check correct function.

NECK RETAINER • Visually inspect for damage. • Remove neck retainer bolt and replace neck retainer nut (annually).

HEAD LINER NOTE: Refer to the head liner disassembly section of the operations and maintenance manual for guidance. HEAD LINER • Remove head liner from helmet (speakers must be remove from pockets prior to head liner removal). • Visually inspect for deterioration and/or damage. • If necessary, replace with a new liner.

NOTE: The liner may be washed as required.

NOSE CLEARING DEVICE (NCD) NOTE: Refer to the nose clearing device disassembly section of the operations and maintenance manual for guidance. O-RINGS (2) • Remove NCD from helmet. • Visually inspect for damage and/or deterioration. • Replace o-rings annually. NEOPRENE PAD • Visually inspect for damage and/or deterioration. • If necessary, replace neoprene pad. NCD BODY • Visually inspect for damage to NCD stem. • Confirm ease of movement. 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. • The oral-nasal mask may be washed as required. • If necessary, replace the oral-nasal mask. NOTE: The oral-nasal mask has a long service life and is not normally replaced annually.

INHALATION VALVE • Remove and visually inspect for damage. All HOUSING spokes of the "wagon wheel" must be present. • If necessary, replace the inhalation valve housing. INHALATION VALVE • Remove and visually inspect for damage and (one way valve) deterioration. • Replace the inhalation valve annually. COMMUNICATIONS NOTE: Refer to the communications disassembly section of the operations and maintenance manual for guidance. SPEAKER AND • Remove and visually inspect the speakers, MICROPHONE microphone, cables and connections. Ensure that contact surfaces are cleaned thoroughly. • During reassembly check the comms system. If sound quality is poor, replace speakers and/or microphone. COMMUNICATIONS • Visually inspect for insulation cracks or damage POSTS and re-tighten each nut from inside. Replace posts and plastic tubing as required. NOTE: There is no requirement to remove the posts unless damaged. COMMUNICATIONS • Visually inspect the internal 4-wire comms TERMINAL BLOCK terminal block for damage. • Replace as required. COMMUNICATIONS • Remove and visually inspect the 4-wire comms BULKHEAD bulkhead connector and cable (if fitted) for damage. • Replace the o-ring annually. • Replace both ferrules annually. 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. HANDWHEEL KNOB • Check condition of the guide hole in the knob. It should be square and firm. If any deterioration or excess play is present, replace knob. WARNING: Knob slippage on the stem may cause hazardous conditions for the diver.

EXHAUST VALVE COVER • Remove the exhaust valve cover from the helmet shell. Visually inspect for damage. Clean as required. • Inspect retainer screws for damage. WATER DUMP EXHAUST • Visually inspect the outer exhaust flapper valve FLAPPER VALVE 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 valve has a long service life and is not normally replaced annually.

DUAL EXHAUST SEAT • Remove the dual exhaust seat from the helmet shell. Visually inspect the seating surface for damage. Clean as required.

DUAL EXHAUST BUSHING • Remove the dual exhaust bushing from the free flow / water dump valve. Visually inspect for damage. Clean as required. 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) • Remove check valves and fittings. • 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) • Replace o-rings on the manifold and port plugs annually. SCREEN • Visually inspect the screen for damage. Wash with soap and water, rinse with fresh water and allow to dry. MANIFOLD HOUSING • Visually inspect for damage. Wash with soap and water, rinse with fresh water and dry by blowing through with compressed air. MANIFOLD GASKET • Replace the manifold gasket annually.

O-RINGS (2) • Replace o-rings on the manifold connecting insert annually.

TEFLON TAPE • Clean all Teflon tape residue from check valves and hose fittings. Apply new Teflon tape prior to reassembly. AIRWAY NOTE: Refer to the airway disassembly section of the operations and maintenance manual for guidance.

AIRWAY • Remove airway assembly from helmet, then visually inspect for damage. • Clean as required. Blow any moisture out of airway assembly using compressed air. SWAGELOCK CONNECTOR • Replace the o-ring annually. 60 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE 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 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANUAL. GX300 REGULATOR CASE • Follow step-by-step instructions for dis-assembly of the regulator case. VALVE SPINDLE ASSEMBLY • Follow step-by-step instructions for dis-assembly of the valve spindle assembly. VALVE DIAPHRAGM • Follow step-by-step instructions for dis-assembly of the valve diaphragm. DEFOGGER NOTE: Refer to the defogger disassembly section of the operations and maintenance manual for guidance. DEFOGGER • Visually inspect the free flow barrel and defogger train for damage. FREE FLOW / WATER DUMP VALVE NOTE: Refer to the free flow / water dump valve disassembly section of the operations and maintenance manual for guidance. FREE FLOW / WATER • Remove the free flow / water dump valve from DUMP VALVE BODY the helmet shell. Disassemble fully and visually inspect all parts for damage. Clean as required. WATER DUMP EXHAUST • Visually inspect the inner exhaust flapper valve for FLAPPER VALVE 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 valve has a long service life and is not normally replaced annually. O-RINGS (3) • Replace all o-rings (3) annually. COPPER WASHERS (2) • Replace both copper washers annually. VALVE SEAT • Visually inspect and check nylon seat condition. • If necessary, replace entire free flow / water dump valve seat. FREE FLOW / WATER • Visually inspect for damage, bends and thread DUMP VALVE STEM condition. • If necessary, replace with new valve stem. TEFLON WASHER • Replace teflon washer annually. BONNET • Visually inspect for damage. 61

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)

STEPS PROCEDURE INITIALS FACE PORT NOTE: Refer to the face port disassembly section of the operations and maintenance manual for guidance.

PORT RETAINER • Visually inspect the port retainer and screws for damage. • Clean as required. O-RING (1) • Visually inspect the groove for damage and clean as required. • Replace the o-ring annually. FACE PORT • Check condition of the face port. • If necessary, wash with soap and water, rinse with fresh water and allow to dry. • Replace the face port if damaged. NOTE: DO NOT scrub, use aerosol or chemicals on the face port, 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 assembly using compressed air.

Signature: Date:

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. 62 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.

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

FACE PORT NOTE: Refer to the face port reassembly section of the operations and maintenance manual for guidance.

O-RING (1) • Lubricate new o-ring with a small amount of Christo-Lube® MCG 111 and install in the grove. The lubricant will help the o-ring to stay in place during the re-assembly procedure. FACE PORT • Place the face port over o-ring making sure to keep the inside/outside (scratched side) orientation.

PORT RETAINER • Torque each screw using an even and opposing pattern, i.e. 12 o’clock position, 6 o’clock position, 9 o’clock position, 3 o’clock etc. 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 • Install exhaust flapper valve ensuring that it is FLAPPER VALVE orientated correctly; the outside edge needs to make a perfect seal with the seat part of the valve body. • DO NOT lubricate the exhaust valve. VALVE SEAT • Install valve seat in the valve body screwing it all the way in. The valve stem may be used for this.

COPPER WASHERS (2) • Install two copper washers in place making sure they seat properly all the way in.

TEFLON WASHER • Install Teflon washer on to the stem shaft.

FREE FLOW / WATER • Place the stem assembly over the valve seat. DUMP VALVE STEM BONNET • Install the bonnet over the stem screwing it hand tight to the valve body.

FREE FLOW / WATER • Install the valve assembly to the right port of the hel- DUMP VALVE BODY met body securing it with the exhaust valve cover and three spacers and screws – this is a temporary measure to assist re-assembly. The exhaust valve cover, spacers and screws will be removed later in the re-assembly procedure. AIRWAY NOTE: Refer to the airway reassembly section of the operations and maintenance manual for guidance.

SWAGELOCK CONNECTOR • Install lubricated o-ring on the Swagelock connector and screw it in to the side port of the free flow valve body. Torque as directed. AIRWAY • Place the airway nut over the Swagelock connector and screw the nut hand tight only, then push the manifold block end inside the helmet shell by bending the tube slightly. Using a metal rod or similar tool is acceptable to provide the necessary leverage. This will not damage the airway. 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 clearing the threads and making sure the outlet port is completely covered by the screen. O-RINGS (2) • Lubricate and install o-rings onto both manifold plugs. MANIFOLD PLUGS • Screw the manifold plug and port plug to the manifold body. Torque both as directed. TEFLON TAPE • Install Teflon tape on both check valves and both hose fittings using the following procedure: • Wrap the pipe threads with approx two turns of Teflon® tape starting after (i.e. back from) the first thread. • Apply the tape with slight tension to allow the tape to fill into the threads. HOSE FITTINGS • Install both hose and scuba fittings into the check valves and tighten as directed. CHECK VALVES (2) • Before installing the check valve/hose fitting assemblies, 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. • Screw both check valves into the manifold body and tighten as directed. O-RINGS (2) • Place both lubricated o-rings into the manifold Insert grooves. MANIFOLD INSERT • Install manifold insert into the airway block socket of the airway assembly through the wall in the helmet shell. MANIFOLD GASKET • Place manifold gasket over the manifold insert and line it up with the 4 bolt holes. MANIFOLD ASSEMBLY • Place the manifold assembly over the manifold insert, line it up with the bolt holes then secure it with two short and long screws. Torque as directed. • Trim any excess gasket material that extrudes past the edge of the manifold body with a sharp blade. 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.

FREE FLOW / WATER • Torque the valve bonnet as directed. Then DUMP VALVE BODY remove the temporarily installed screws, spacers and exhaust valve cover.

DUAL EXHAUST BUSHING • Install dual exhaust bushing over the valve bonnet.

DUAL EXHAUST SEAT • Install the dual exhaust seat (plate) over the bushing and ensure that the screw holes are aligned.

WATER DUMP EXHAUST • Install exhaust flapper valve ensuring that it is FLAPPER VALVE orientated correctly; the outside edge needs to make a perfect seal with the dual exhaust seat. DO NOT lubricate the exhaust valve.

EXHAUST VALVE COVER • Reinstall the exhaust valve cover, use the five spacers and five screws to secure it in place. • Torque each screw as directed using an even pattern.

HANDWHEEL KNOB • Install the hand wheel knob. Take care not to cross thread the nut.

DEFOGGER NOTE: Refer to the defogger reassembly section of the operations and maintenance manual for guidance.

DEFOGGER • Before installation make sure that both the barrel and the train are not damaged, the holes are not blocked, and the train tubes are glued securely to the train guide. 66 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS

NEOPRENE PAD • Install new neoprene pad to the metal pad of the shaft.

O-RINGS (2) • Lubricate and place two o-rings on the NCD shaft.

NCD BODY • NCD assembly is ready for installation after the oral-nasal mask is in place.

ORAL-NASAL MASK NOTE: Refer to the oral-nasal mask reassembly section of the operations and maintenance manual for guidance.

INHALATION VALVE • Install inhalation valve into the inhalation valve (one way valve) housing. Ensure that the valve is installed on the correct side of the housing. INHALATION VALVE • Install inhalation valve housing assembly into HOUSING the oral nasal mask, ensuring that the valve is installed correctly, i.e. it must allow air to flow into the oral-nasal mask. MICROPHONE • Install microphone into the oral-nasal mask.

ORAL-NASAL • Install oral-nasal mask into the helmet. 67

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)

STEPS PROCEDURE INITIALS

COMMUNICATIONS NOTE: Refer to the communications reassembly section of the operations and maintenance manual for guidance. COMMUNICATIONS • Install a lubricated o-ring onto the comms BULKHEAD bulkhead, then screw the bulkhead into the modified nut in the inside of the helmet shell. Torque as directed. • When fitting a 4-wire comms cable, a small quantity of household dishwashing detergent applied to the outside of the cable will help the ferrules to slide along the cable.

COMMUNICATIONS • Install the communication posts with plastic POSTS tubing into the helmet shell. COMMUNICATIONS • Install the communication terminal block over TERMINAL BLOCK the communication posts. SPEAKER AND • Install speakers and microphone wire connectors MICROPHONE to the terminal block.

HEAD LINER NOTE: Refer to the head liner reassembly section of the operations and maintenance manual for guidance.

HEAD LINER • When correctly positioned the front edges of the headliner should be just touching the oral-nasal mask. The headliner should always be pre-adjusted by the diver. NECK RETAINER AND LOCKING SYSTEM NOTE: Refer to the neck retainer and locking system reassembly section of the operations and maintenance manual for guidance.

LATCH CATCHES • If removed for maintenance, reinstall left and right latch catches. Torque the screws as directed. • Check the correct operation of the latch catches after re-assembly. NECK RETAINER • Check that the neck retainer is not bent before installation. A bent neck retainer may be straightened in a vise. 68 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued) STEPS PROCEDURE INITIALS NECK DAM AND QUAD RING NOTE: Refer to the neck dam and quad ring reassembly section of the operations and maintenance manual for guidance. NECK DAM AND QUAD Re-installation during annual maintenance: RING • Check the condition of the neck seal. Replace as necessary (see below). • Install a lightly lubricated quad ring into the groove in the upper neck ring. NOTE: The quad ring has a long service life and is not normally replaced annually. • Install the chin strap. Torque screws as directed. NEOPRENE NECK SEAL REPLACEMENT UPPER NECK RING • Blow through all threads with compressed air to ensure that there is no debris inside them. • Position the upper neck ring with the holes facing up. • Place the neck seal (with the seam tape on the inside) on top of the upper neck ring and line up the holes. BOTTOM NECK RING • Place the side of the lower neck ring with the screw marks face up over the neoprene neck seal and line up the holes. • Apply a small amount of Christo-Lube® MCG 111 through each hole in the neoprene neck seal (or to each screw) to make sure the screws do not bind with the neoprene during installation. • Starting with two screws, front and back, insert screws all the way around until all screws are in place. Torque all screws as directed. NECK SEAL • Trim any excess neoprene after all screws are tight and torqued correctly. • Since neoprene compresses, the torque on each screw should be rechecked after 24 hours. • Turn neck seal rightside out. QUAD RING • Install lubricated quad ring into the groove on the upper neck ring.

Signature: Date:

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. 69

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: (Print Name)

HELMET FINAL TESTING When the helmet is completely reassembled, the following tests must be conducted to confirm that it performs correctly.

PREPARATIONS • Ensure all fittings are secure and the helmet is completely reassembled. • Remove the neck dam from the helmet. • Attach a regulated breathing gas source, between 9.2 - 9.8 BAR (133 - 142 PSI), to the helmet SCUBA check valve. • Ensure the free flow / water dump valve is closed. • Open the gas supply to the helmet. • Open the free flow / water dump valve and confirm that there is a powerful flow of gas coming out of the defogger train. • Close the free flow / water dump valve. LEAK CHECK • Ensure the gas supply to the helmet is open, listen for any audible external and internal leaks. • Apply leak test solution (e.g. soap and water) to external gas fittings and connections, including manifold body and check valves. • Apply leak test solution to internal gas fittings and connections, including airway assembly, Swagelock connector, free flow / water dump valve assembly, and second stage regulator connection. • No leaks are permitted. Any leaks must be investigated and resolved. 70 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

STEPS PROCEDURE INITIALS

HELMET FINAL TESTING (continued) When the helmet is completely reassembled, the following tests must be conducted to confirm that it performs correctly.

SECOND STAGE • Slowly depress the purge button to full extent and REGULATOR CHECK confirm a sufficient audible flow of gas.

COMMUNICATIONS • Fit the head liner into the helmet. CHECK • Connect a communications cable and surface communications unit. • Check all communications function correctly.

NOTE: Insert speakers into head liner after communications check is complete.

FINAL CHECK • Fit the neck dam assembly into the helmet. • Check that the neck retainer operates correctly and close the latch catches. • Conduct a Functional Bench Test of the Helmet and Regulator ("Neck Dam Pull Test"). See Functional Bench Test of the Helmet and Regulator section of this manual. • On completion of the Neck Dam Pull Test close the air / gas supply and vent the helmet. • When all pressure is vented from the system, close all valves. • Then "bunch" the neck seal tightly again, pull it out, and hold it in place to ensure that the exhaust valves in the helmet are functioning correctly. There should be no leak into the helmet from the outside. • 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.

Signature: Date:

Technician Comments (e.g. Specific items noted during maintenance): Comments: 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" tightly to ensure that the open end is "sealed".

3. Slowly pull the bunched end of the neck seal out to full extension, then push back fully into the helmet. Repeat this 3 or 4 times. The regulator should be heard to open and close (i.e. inhale and exhale). This pull and push action simulates a diver breathing in the helmet. A properly serviced and adjusted regulator should deliver air upon deep inhalation without excessive inhalation effort, free flow or "fluttering" of the second stage. 72 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) Appendix G Neck Dam Appendix H Welding Shield Kit Appendix I Welding Shield Assembly Installation Instructions Appendix J Free Flow Plug Insert Kit Installation Instructions Appendix K Camera / Light Bracket Installation Instructions Appendix L Terminal Block Communications Kits Appendix M Twist-On Communications Kits Appendix N Communications Kit Installation Instructions Appendix O Torque Specifications Appendix P Recommended Cleaners and Lubricants Appendix Q Cleaning and Lubricating Appendix R Annual Service Kit Appendix S Field Spares Kit Appendix T Maintenance Log Sheet 73

APPENDIX A – MAIN ASSEMBLIES

SS Blank Plug 90 in lb (10 Nm) 140 in lb (16 Nm) 90 in lb (10 Nm) 28 4 2 MANIFOLD 27 5 SEE APPENDIX C

26 25 ft lb (34 Nm) 6 8 9 25 24 10 80 in lb (9 Nm)

INNER COMPONENTS 1 SEE APPENDIX B

SECOND STAGE SEE APPENDIX E 23

140 in lb (16 Nm) 4 NOSE CLEARING DEVICE SEE APPENDIX F 5

NECK DAM APPENDIX G FREE FLOW / WATER DUMP VALVE 22 SEE APPENDIX D

3 21 7 8 9 10

80 in lb (9 Nm) 15

16 17 18

20a 19 11 14 20b 13 DOUBLE EXHAUST / 12 20c 45 in lb WATER DUMP VALVE 11 20 (5 Nm) PN 400111 45 in lb (5 Nm)

KEY # QTY P/N DESCRIPTION KEY # QTY P/N DESCRIPTION 1 1 400001 SHELL, HELMET 17 5 400099 RING, SPACER (5 PK) 2 1 400118 LATCH, LEFT 18 1 400047 VALVE, WATER DUMP / FLAPPER EXHAUST 3 1 400119 LATCH, RIGHT 19 1 400010 COVER, EXHAUST VALVE 4 2 400113 SCREW, LATCH 5/16" - 18 X 3/4" LONG 20 1 AP0270 HANDWHEEL ASSEMBLY 5 2 400134 WASHER, LOCK 5/16" (5 PK) 20a 1 N/A KNOB, HANDWHEEL 6 1 400116 BASE, LATCH, LEFT 20b 1 N/A SPRING 7 1 400117 BASE, LATCH, RIGHT 20c 1 N/A NUT 8 2 400005 SPRING, LATCH (5 PK) 21 1 400114 RETAINER, NECK, MOD 1 9 2 400120 WASHER, LATCH SPRING (2 PK) 22 1 400004 NUT, NECK RETAINER (5 PK) 10 2 400192 SCREW, BUTTON CAP (5 PK) 23 1 400003 BOLT, NECK RETAINER (5 PK) 11 17 400015 SCREW, RETAINER PORT (5 PK) 24 2 400016 POST, COMMUNICATION ASSEMBLY 12 1 400014 RETAINER, PORT 25 1 400031 O-RING, MANIFOLD PLUG (10 PK) 13 1 400013 PORT, FACE 26 1 400017 BULKHEAD, COMM W/ SS BLANK PLUG ASSY 14 1 400012 O-RING, FACE PORT 27 1 400127 FERRULES, LARGE & SMALL (10 pk) 15 1 400097 BUSHING, DUAL EXHAUST 28 1 400122 CAP & PLASTIC FERRULES, BULKHEAD ASSY 16 1 400098 SEAT, DUAL EXHAUST N/S 1 AP0300 REG, GX300

Part numbers in BOLD ITALICS indicate standard overhaul replacement part. 74 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

APPENDIX B – INNER COMPONENTS

29 40

COMMUNICATIONS KITS SEE APPENDICES L & M

38 30

37 VALVE ASSEMBLY PN AP0271 36 INCLUDES KEY # 36 & 37

32 33 34 45 in lb (5 Nm) 35

KEY # QTY P/N DESCRIPTION

29 1 400152 WIRE TERMINAL BLOCK 30 1 400130 SPEAKER RIGHT 31 1 400138 AIRWAY ASSEMBLY 32 1 400131 MICROPHONE 33 1 400021 SWAGELOCK CONNECTOR 34 1 400024 BARREL, FREE FLOW 35 1 400022 O-RING, SWAGELOCK CONN & PORT PLUG (10 PK) 36 1 AP6223 VALVE, INHALATION 37 1 AP2537 HOUSING, INHALATION VALVE 38 1 400023 TRAIN, DEFOGGER 39 1 400025 MASK, ORAL NASAL 40 1 400129 SPEAKER LEFT N/S 1 400028 HEAD LINER

Part numbers in BOLD ITALICS indicate standard overhaul replacement part. 75

APPENDIX C – MANIFOLD

41 41 80 in lb (9 Nm)

43 44 90 in lb (10 Nm) 46 44 25 42 45 80 in lb (9 Nm) 42 47

45 in lb (5 Nm) 49 50

50 52

51 53

KEY # QTY P/N DESCRIPTION

41 2 400036 SCREW, HEX, MANIFOLD (5 PK) 42 2 400035 SCREW, HEX, MANIFOLD (5 PK) 43 1 400033 INSERT, MANIFOLD 44 2 400034 O-RING, MANIFOLD CONNECTOR (10 PK) 45 1 400037 GASKET, MANIFOLD 46 1 400030 PLUG, MANIFOLD (LARGE) 25 1 400031 O-RING, MANIFOLD PLUG (10 PK) 47 1 400032 SCREEN 48 1 400029 BODY, MANIFOLD 35 1 400022 O-RING, SWAGELOCK CONN & PORT PLUG (10 PK) 49 1 400039 PORT PLUG 50 2 400040 VALVE, CHECK 51 1 400042 FITTING, HOSE 52 1 400041 FITTING, SCUBA 53 2 400043 CAP, FITTING, BRASS

Part numbers in BOLD ITALICS indicate standard overhaul replacement part. 76 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

APPENDIX D – FREE FLOW / WATER DUMP VALVE

18 58 57

59 59 60

61 62 NOTE: A double exhaust / water dump valve is fitted 35 ft lb (47 Nm) 63 to the G3000SS helmet - See Appendix A.

KEY # QTY P/N DESCRIPTION

54 1 400045 O-RING, EXHAUST, SMALL (10 PK) 55 1 400044 BODY, FREE FLOW / WATER DUMP VALVE 56 1 400046 O-RING, EXHAUST, LARGE (10 PK) 18 1 400047 VALVE, WATER DUMP / FLAPPER EXHAUST 57 1 400048 RING, WATER DUMP / FLAPPER VALVE SNAP 58 1 400049 SEAT, FREE FLOW / WATER DUMP VALVE 59 2 400050 WASHER, COPPER (5 PK) 60 1 400051 STEM, FREE FLOW / WATER DUMP VALVE 61 1 400053 WASHER, TEFLON (5 PK) 62 1 400052 O-RING, FREE FLOW / WATER DUMP VALVE STEM (10 PK) 63 1 400054 BONNET, FREE FLOW / WATER DUMP VALVE

Part numbers in BOLD ITALICS indicate standard overhaul replacement part. 77

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. 78 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

APPENDIX F – NOSE CLEARING DEVICE (NCD)

66 66

KEY # QTY P/N DESCRIPTION

64 1 400077 NOSE PAD, NEOPRENE (5 PK) 65 1 400140 NOSE CLEARING DEVICE (WELDED) 66 2 400074 O-RING, NOSE CLEARING DEVICE (NCD) (10 PK) 67 1 400073 KNOB, NCD

Part numbers in BOLD ITALICS indicate standard overhaul replacement part. 79

APPENDIX G – NECK DAM

70 73

74 71

75 20 in lb (2 Nm)

76 72 20 in lb (2 Nm) 74

20 in lb (2 Nm)

KEY # QTY P/N DESCRIPTION

68 1 400078 RING, QUAD 69 1 400079 RING, NECK UPPER 70 1 400080 SEAL, NECK 71 1 400081 RING, NECK LOWER 72 18 400082 SCREW, NECK RING LOWER (5 PK) 73 2 400085 BUCKLE, STRAP 74 2 400084 BUSHING, BUCKLE STRAP (5 PK) 75 2 400083 SCREW, BUCKLE STRAP (5 PK) 76 1 400086 STRAP, NYLON W/ D-RINGS 80 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

APPENDIX H – WELDING SHIELD KIT

78 77 80 45 in lb (5 Nm) 83 82 79

45 in lb (5 Nm) 81 11 80

45 in lb (5 Nm) 80 in lb (9 Nm) 42 83

KEY # QTY P/N DESCRIPTION

77 2 400089 BRACKET, LENS HOLDING (2 PK) 78 1 400090 GASKET, WELDING LENS 79 1 400088 LENS, WELDING 80 2 400092 HINGE, BLOCK WELDING LENS (2 PK) 11 1 400015 SCREW, RETAINER PORT (5 PK) 81 1 400095 SHIELD, WELDING SPRING 82 2 400093 SCREW, HINGE BLOCK MOUNTING (5 PK) 83 2 400094 SCREW, HINGE (5 PK) 84 1 400087 BODY, WELDING SHELL (SHIELD) 42 2 400035 SCREW, HEX, MANIFOLD (5 PK) 81

APPENDIX I SHIELD, WELDING ASSEMBLY (P/N 400102) 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.

KIT CONTENTS Part # Item Description Qty per Kit 400087 Body, Welding Shell (Shield) 1 400088 Lens, Welding 1 400089 Bracket, Lens Holding 2 400090 Gasket, Welding Lens 1 400035 Screw, Hex, Manifold 2 400092 Hinge Block, Welding Lens 2 400093 Screw, Hinge Block Mounting 2 400094 Screw, Hinge 2 400095 Shield, Welding Spring 1 400015 Screw, Retainer Port 1 Step-by-Step Assembly Instructions

1. Use a Phillips # 3 screwdriver to 2. Install shield welding spring 3. Line up welding lens assembly remove three retainer port screws (81) and retainer port screw (11). with the port retainer (12). (11) from top of helmet retainer Tighten to 45 in lb (5 Nm) using Note: Hinge blocks (80) port (12). an inch pound torque wrench and and hinge block mounting Phillips # 3 screwdriver bit. screws (82) pre-mounted to shield.

4. Tighten left and right hinge 5. Tighten left and right hinge 6. Confirm welding shield opens block mounting screws (82) to 45 screws (83) to 45 in lb (5 Nm) us- and closes correctly. in lb (5 Nm) using an inch pound ing an inch pound torque wrench torque wrench and 1/4" flat blade and Phillips #3 screw driver bit. screwdriver bit. 82 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

APPENDIX J FREE FLOW PLUG INSERT KIT (P/N 400112) 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.

CAUTION: When the helmet is used in free flow mode the free flow valve must be open and properly adjusted at 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 per Kit N/A Plug, Insert, Free Flow 1 400046 O-ring, Exhaust (Large) 1 17306 Hook Fastener, 2.0 in Blk, Pressure Sensitive 1 17308 Loop Fastener, 1.0 in Blk, Pressure Sensitive 1 400009 Screw, Exhaust Valve Cover (5 pk) 1 400011 Cover, Regulator 1

Step-by-Step Assembly Instructions

1. Remove knob (67) from nose 2. Remove NCD (65) from helmet 3. Remove oral-nasal mask (39) clearing device (65). shell (1). from the regulator.

NOTE: Refer to the separate Apeks Technical Man- ual: GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET - MAINTENANCE MANU- AL for guidance on removal of the GX300 regulator. 4. Remove microphone (32) from 5. Remove the second stage oral-nasal mask (39). regulator. 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. hook and loop strip on barrel.

9. Install free flow plug into helmet 10. Place regulator cover onto 11. Tighten exhaust valve cover shell (1). Ensure hook and loop regulator port. screws using an inch pound torque strip is facing inward. wrench and Phillips #3 screwdriver bit to 45 in lb (5 Nm).

12. Place hook and loop tab on 13. Place microphone (32)on 14. Reinstall NCD (65) into the base of microphone (32). free flow plug. helmet shell (1)..

15. Place NCD knob (67) on NCD 16. Free flow kit installed into (65) to secure in place. helmet. 84 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

APPENDIX K CAMERA/LIGHT BRACKET (P/N 400107) INSTALLATION INSTRUCTIONS

Step-by-Step Assembly Instructions

1. Remove two retainer port screws NOTE: Brackets may 2. Line up bracket holes with hel- (11) from top corner of helmet using a be bent to shape as met retainer holes. Phillips #3 screwdriver. required.

3. Replace the two retainer port 4. Right hand bracket installed. screws (11) and tighten using an inch pound torque wrench and Phillips #3 screwdriver bit to 45 in lb (5 Nm).

5. Left hand bracket installed. 6. Left and Right brackets. 85

APPENDIX L – TERMINAL BLOCK COMMUNICATIONS KITS TERMINAL BLOCK HI-USE COMMUNICATIONS MODULE KIT (P/N 400150)

29 Hand tight & 1¼ turn with wrench

28 85 86

KEY # QTY PART # DESCRIPTION

28 1 400122 CAP & PLASTIC FERRULES, BULKHEAD ASSY 85 1 400133 TUBING PLASTIC, PRE-CUT (10PK) 29 1 400152 WIRE TERMINAL BLOCK 86 1 400126 CABLE ASSY, OTS COMMS, HI-USE

TERMINAL BLOCK MARSH MARINE COMMUNICATIONS MODULE KIT (P/N 400151) Hand tight & 1¼ turn with wrench

28 85 87

KEY # QTY PART # DESCRIPTION

28 1 400122 CAP & PLASTIC FERRULES, BULKHEAD ASSY 85 1 400133 TUBING PLASTIC, PRE-CUT (10PK) 29 1 400152 WIRE TERMINAL BLOCK 87 1 400125 CABLE ASSY, OTS COMMS, MARSH MARINE

WIRE TERMINAL BLOCK (P/N 400152)

KEY # QTY PART # DESCRIPTION 85 1 400133 TUBING PLASTIC, PRE-CUT (10PK) 29 1 400152 WIRE TERMINAL BLOCK 86 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

88 28 89

KEY # QTY Part # DESCRIPTION

28 1 400122 CAP & PLASTIC FERRULES, BULKHEAD ASSY 88 2 400148 TWIST-ON CONN KIT, 2 CONNS ALONE 89 1 400146 CABLE ONLY ASSY, TWIST ON, HI-USE

TWIST-ON MARSH MARINE COMMUNICATIONS MODULE KIT (P/N 400145)

Hand tight & 1¼ turn with wrench

88 28 90

KEY # QTY Part # DESCRIPTION

28 1 400122 CAP & PLASTIC FERRULES, BULKHEAD ASSY 88 2 400148 TWIST-ON CONN KIT, 2 CONNS ALONE 90 1 400147 CABLE ONLY ASSY, TWIST ON, MARSH MARINE 87

APPENDIX N 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.

4-Wire Terminal Block Kit Installation Instructions Installing Terminal Block and Cable Assembly

1. Use a 3/8" nut driver to remove the communication post hex nuts and communication posts (24) from the helmet shell (1). Remove the old plastic tubing (85) from the communication posts and replace it with new plastic tubing from the communications kit. Re-install the communication posts into the helmet shell. Insert the communication posts through the holes in the terminal block (29) 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).

Figure 1 Figure 2

2. Using a 11/16" deep socket and driver, remove the SS cap from the comms bulkhead (26).

3. Use a 15/16" deep socket and foot pound torque wrench, retorque the comms bulkhead (26) to 25 ft lb (34 Nm).

4. Insert the connector cable assembly (86 or 87) through the bulkhead cap (28). Install the ferrules onto the connector cable in the following order: small ferrule (small side towards helmet), then large ferrule (small side towards helmet). Insert the connector cable through the comms bulkhead (26). Tighten the bulkhead cap hand tight, then 1 1/4 turns further with a 11/16" wrench to secure the cable.

5. Connector cable assembly is available with Hi-Use (86) (Fig. 3) or Marsh Marine (87) (Fig. 4) connector.

Figure 3 Figure 4 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. Securely tighten communication post hex nuts to terminal block with a 3/8" nut driver. Figure 5

CAUTION: DO NOT overtighten the communication post hex nuts to the terminal block.

Mic

Speaker (right)

Speaker (left) Figure 6

4-Wire Twist-On Kit Installation Instructions Installing Cable Assembly 1. Using a 11/16" deep socket and driver, remove the SS cap from the comms bulkhead (25).

2. Use a 15/16" deep socket and foot pound torque wrench, retorque the comms bulkhead (26) to 25 ft lb (34 Nm).

3. Insert the connector cable assembly (89 or 90) through the bulkhead cap (28). Install the ferrules onto the connector cable in the following order: small ferrule (small side towards helmet), then large ferrule (small side towards helmet). Insert the connector cable through the comms bulkhead (26). Tighten the bulkhead cap hand tight, then 1 1/4 turns further with a 11/16" wrench to secure the cable.

4. Connector cable assembly is available with Hi-Use (89) (Fig. 7) or Marsh Marine (90) (Fig. 8) connector.

Figure 7 Figure 8 89

5. Install connector cable lug rings onto the communication 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 communication posts with a 3/8" nut driver. Figure 9

CAUTION: DO NOT overtighten the communication post hex nuts to the communication posts.

Installing Twist-On Connectors

1. Wire the microphone (32) to the connector cable assembly (89 or 90) per the wiring diagram (Fig. 11). Place stripped wires together with the ends of insulation even. Twist connector (88) (Fig. 10) onto wires pushing firmly until hand-tight. Wipe sealant in and around conductors and connector open while tightening. Figure 10

NOTE: Pre-twisting connector cable wires is not necessary.

NOTE: Twist-on connectors are internally treated with water proof sealant.

Mic

Speaker (right)

Speaker (left)

Figure 11 2. Hi-Use pin configuration (Fig. 12) and Marsh Marine pin configuration (Fig. 13).

Figure 12 Figure 13 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. Securely tighten communication post hex nuts to terminal block with a 3/8" nut driver. Figure 14

CAUTION: DO NOT overtighten the communication post hex nuts to the terminal block.

Mic

MicMic Speaker (right) SpeakerSpeaker (right)(right) Speaker (left) SpeakerSpeaker Figure 15 (left)(left)

2. Hi-Use pin configuration (Fig. 16) and Marsh Marine pin configuration (Fig. 17).

Figure 16 Figure 17 91

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)

400021 Swagelock Connector (33) 45 in lb (5 Nm) Fitted into free flow / water dump valve body (55) 400030 Manifold Plug (46) 90 in lb (10 Nm)

400035 Screw, Hex, Manifold (42) 80 in lb (9 Nm)

400036 Screw, Hex, Manifold (41) 80 in lb (9 Nm)

400192 Screw, Button Cap (10) 80 in lb (9 Nm)

400039 Port Plug (49) 45 in lb (5 Nm)

400082 Screw, Neck Ring, Lower (72) 20 in lb (2 Nm)

400083 Screw, Buckle Strap (75) 20 in lb (2 Nm)

400093 Screw, Hinge Block Mounting (82) 45 in lb (5 Nm)

400094 Screw, Hinge (83) 45 in lb (5 Nm)

400128 SS Blank Plug (N/A) 90 in lb (10 Nm) SS blank plug for bulkhead connector Part # DESCRIPTION / KEY # TORQUE (FT LB) NOTE

400017 Bulkhead Connector (26) 25 ft lb (34 Nm)

400054 Bonnet, Free Flow / Water Dump Valve (63) 35 ft lb (47 Nm)

Part # DESCRIPTION / KEY # TORQUE (SEE NOTE) NOTE

400122 Cap & Ferrules Bulkhead Assy (28) See Note Cable installed hand tight, then 1¼ turn with wrench 400138 Swivel Nut (Airway Assy) (29) See Note Tighten swivel nut until it bottoms out on swagelock connector 400040 Check Valve (50) See Note Hand tight, then 1½ turn with wrench 400041 Fitting, Hose (51) See Note Hand tight, then 1½ turn with wrench 400042 Fitting, SCUBA (52) See Note Hand tight, then 1½ turn with wrench 92 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 All o-rings Lubrication Technologies 310 Morton Street Jackson, OH 45640 (800) 477-8704

CAUTION: Silicone rubber requires no lubrication or preservative treatment. DO NOT apply grease or spray to silicone rubber parts. Doing so may cause a chemical breakdown and premature deterioration of the material.

CAUTION: Do not use muriatic acid for the cleaning of any parts. Even if strongly diluted, muriatic acid can harm chrome plating and may leave a residue that is harm- ful to o-ring seals and other parts.

Acid bath for reusable stainless steel White distilled vinegar “Household” grade and brass parts.

Degreaser for brass and stainless steel Non-ionic Liquid dishwashing parts; general cleaning solution for plastic “Household” grade detergent (diluted with warm water) and rubber. 93

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). Clean ultrasonically for 5 minutes (max 10 minutes). DO NOT place plastic, rubber, silicone or anodized aluminium parts in vinegar. 3. Remove parts from the ultrasonic cleaner and rinse with fresh water. If tap water is extremely “hard,” place the parts in a bath of distilled water to prevent any mineral residue. Agitate lightly, and allow to soak for 5-10 minutes. Remove and blow dry with low pressure 25 PSI (1.7 BAR) filtered air. Inspect closely 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 only a soft nylon toothbrush to scrub away any deposits. Rinse in fresh water and thoroughly blow dry, using low pressure filtered air.

CAUTION: Do not place plastic and rubber parts in acid solutions. Doing so may alter the physical properties of the component, causing it to prematurely degrade and/or break.

Lubrication and Dressing All o-rings should be lubricated with Christo-Lube® MCG 111. Dress the o-rings with a very light film of grease, and remove any visible excess by running the o-ring between thumb and forefinger. Avoid applying excessive amounts of Christo-Lube grease, as this will attract particulate matter that may cause damage to the o-ring.

*Soapy water is defined as “household” grade liquid dishwashing detergent diluted in warm water. 94 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

APPENDIX R G3000SS ANNUAL SERVICE KIT (P/N 400180) G3000SS ANNUAL SERVICE KIT W/O REGULATOR (P/N 400183)

The Key # (column D) is provided to assist with correct parts identification and refers to the relevant Exploded Parts Diagram (Appendices A thru F).

A B C D

Part # Item Description Qty per Kit Key #

400004 Nut, Neck Retainer 1 22

400012 O-ring, Face Port 1 14

400022 O-ring, Swagelock Connector & Port Plug 2 35

AP6223 Valve, Inhalation 1 36

400031 O-ring, Manifold Plug 2 25

400034 O-ring, Manifold Connector 2 44

400037 Gasket, Manifold 1 45

400045 O-ring, Exhaust (Small) 1 54

400046 O-ring, Exhaust (Large) 1 56

400050 Washer, Copper 2 59

400052 O-ring, Stem, Free Flow / Water Dump Valve 1 62

400053 Washer, Teflon 1 61

400074 O-ring, Nose Clearing Device (NCD) 2 66

400127 Ferrules (Set of Small & Large) 1 27

AP0300/K GX300 Regulator Service Kit 1 See Note

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. 95

APPENDIX S G3000SS FIELD SPARES KIT (P/N 400185)

The Key # (column D) is provided to assist with correct parts identification and refers to the relevant Exploded Parts Diagram (Appendices A thru F).

A B C D

Part # Item Description Qty per Kit Key # 400015 Screw (5 Pack) 12/24-5/8” 1 11

400016 Post, Communication 2 24

400025 Mask, Oral-Nasal 1 39

400028 Liner, Head Medium 1 N/S

400047 Valve, Flapper Exhaust 2 18

400051 Stem, Free Flow Valve 1 60

400077 Pad, Nose Neoprene (5 Pack) 1 64

400078 Ring, Quad 1 68

400080 Seal, Neck 1 70

400086 Chin Strap, Nylon 1 76

400127 Ferrules Nylon (10 pack) 1 27

400129 Speaker, Left 1 40

400130 Speaker, Right 1 30

400131 Microphone 1 32

400183 Kit, Annual Service G3000SS W/O Reg 1 N/S

AP0300/K GX300 Regulator Overhaul Kit 1 N/S

AP0271 Oral Nasal Valve Assembly 1 36 & 37

AP0270 Handwheel Assembly 1 20

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. 3. The contents are based on a recommended quantity of 1 kit per 2 to 3 helmets. 4. Annual service kits for the helmet and regulator are included in the main kit. It is recommended that these be used as a source of ready-use spares for unplanned defect rectification. Separate service kits should be kept untouched for actual annual servicing. 96 Aqua Lung G3000SS Diving Helmet Operations & Maintenance Manual

APPENDIX T G3000SS MAINTENANCE LOG SHEET Date 20/05/15 DD/MM/YY HELMET NUMBER HELMET Signature Joe Tech Technician (Print Name) (Print - ANNUAL Inspection - Checklist and Maintenance Checklist 6 Checklist MAINTENANCE LOG SHEET LOG MAINTENANCE AQUA LUNG G3000SS DIVING HELMET AQUA COMMENTS (e.g. or damage items of concern identifed during maintenance) - USE MULTIPLE NEEDED LINES AS Face port scratched but serviceable - MONTHLY Inspection Checklist and Maintenance or MONTHLY - Monthly UNPLANNED REPAIR REPAIR UNPLANNED MONTHLY - ANNUAL - MONTHLY - ANNUAL (identify which applies) one Use this 2nd Stage (includingRegulator) on each log completed maintenance Diving G3000SS Helmet sheet record to GX300 Aqua Lung G3000SS Operations & Maintenance (O&M) Manual &Aqua (O&M) Operations Maintenance Lung G3000SS Checklist 5 Checklist : : : NUMBER e.g. AQ100100 HELMET SERIAL NUMBER or LOCAL NUMBER or LOCAL Technician Note Technician Reference Checklists 97

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 400011 Double Water Dump Exhaust Assembly 400012 O-ring, Face Port 400013 Port, Face 400014 Retainer, Port 400015 Screw, Retainer Port (5 Pack) 400016 Post, Communication Assembly 400017 Bulk Head, Communications w/ SS Plug Assembly 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 Housing, Inhalation Valve AP6223 Valve, Inhalation AP0270 Handwheel Assembly (includes Key # 20a, 20b & 20c) AP0271 Valve Assembly (includes Key # 36 & 37) AP0300 Reg, GX300 400028 Liner, Head 400029 Body, Manifold 400030 Plug, manifold (Large) 400031 O-ring, Manifold Plug (10 Pack) 400032 Screen 400034 O-ring, Manifold Connector (10 Pack) 400035 Screw, Hex, Manifold (5 Pack) 400036 Screw, Hex, Manifold (5 Pack) 400037 Gasket, Manifold 400039 Plug, Port 400040 Valve, Check 400041 Fitting, SCUBA 400042 Fitting, Hose 400043 Cap, Fitting, Brass 400044 Body, Free Flow / Water Dump Valve 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 Seat, Free Flow / Water Dump Valve 400050 Washer, Copper (5 pack) 400051 Stem, Free Flow / Water Dump Valve 400052 O-ring, Free Flow / Water Dump Valve Stem (10 Pack) 400053 Washer, Teflon (5 pack) 400054 Valve, Free Flow / Water Dump Bonnet 400073 Knob, NCD 400074 O-ring, Nose Clearing Device (NCD) (10 Pack) 400077 Pad, Nose Neoprene (5 Pack) 400078 Ring, Quad 400079 Ring, Neck Upper 400080 Seal, Neck 400081 Ring, Neck Bottom 400082 Screw, Neck Ring Lower (5 Pack) 400083 Screw, Buckle 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, Welding Lens 400092 Hinge Block, Welding Lens (2 Pack) 400093 Screw, Hinge Block Mounting (5 pack) 400094 Screw, Hinge (5 Pack) 400095 Spring, Welding Shield 400097 Bushing, Dual Exhaust 400098 Seat, Dual Exhaust 400099 Ring, Spacer (5 Pack) 400102 Shield, Welding Assembly 400103 Neck Ring, Assembly 400104 Set, Communication 400107 Bracket, Light/Camera 400109 Locking System, Left 400111 Kit, Double Exhaust 400112 Kit, Plug Insert Free Flow 400113 Screw, Latch 5/16" - 18 x 3/4" Long (5 Pack) 400114 Retainer, Neck Ring, Mod 1 400120 Washer, Latch Spring (2 Pack) 99

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 Speaker, Right 400131 Microphone 400132 Locking System, Right 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 Kit, Twist-On, Hi-Use 400145 Comms Module Kit,Twist-On, Marsh Marine 400146 Cable Only Assy, Twist-On, Hi-Use 400147 Cable Only Assy, Twist-On, Marsh Marine 400148 Twist-On Conn Kit, 2 Conns Alone 400150 Comms Module Kit, Terminal Block, Hi-Use 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) 100 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

Helmet Flotation Bag Standard Helmet Bag P/N 400805 P/N 400804 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" MNPT, Yellow • P/N 400165 - Fitting, QD, Female, 1/4" FNPT P/N 400166 - Fitting, QD, Male, 1/4" FNPT AQUA LUNG G3000SS HELMET OPERATIONS & MAINTENANCE MANUAL

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