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Rev. 8/12
GORSKI G2000SS HELMET
TECHNICAL MAINTENANCE MANUAL
2 Gorski G2000SS Diving Helmet Technical Manual

COPYRIGHT NOTICE

This manual is copyrighted, all rights reserved. It may not, in whole or in part, be copied, photocopied,
reproduced, translated, or reduced to any electronic medium or machine readable form without prior
consent in writing from Aqua Lung America, Inc. It may not be distributed through the internet or
computer bulletin board systems without prior consent in writing from Aqua Lung America.

© 2012 AQUA LUNG AMERICA, INC.


GORKSI G2000SS DIVING HELMET TECHNICAL MANUAL, PN 400143

Gorski G2000SS Diving Helmet PN 400000

You can contact a Technical Advisor via e-mail at:

rbedard@aqualung.com
lgorski@aqualung.com

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 dam-


age 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����������������������������������������������������������������������������������������������������������������������������������������������������5
II. WARRANTY INFORMATION���������������������������������������������������������������������������������������������������������������������������������������������5
III. HELMET SET-UP AND OPERATION�������������������������������������������������������������������������������������������������������������������������������6
IV. HELMET MAINTENANCE AND PARTS LIST������������������������������������������������������������������������������������������������������������������7
V. STEP-BY-STEP ASSEMBLY INSTRUCTIONS�����������������������������������������������������������������������������������������������������������������9
A. SECOND STAGE REGULATOR������������������������������������������������������������������������������������������������������������������������������10
B. FREE FLOW / EXHAUST VALVE�����������������������������������������������������������������������������������������������������������������������������13
C. MANIFOLD���������������������������������������������������������������������������������������������������������������������������������������������������������������15
D. DEFOGGER��������������������������������������������������������������������������������������������������������������������������������������������������������������16
E. ORAL-NASAL MASK�����������������������������������������������������������������������������������������������������������������������������������������������17
F. NOSE-CLEARING DEVICE (NCD)���������������������������������������������������������������������������������������������������������������������������19
G. FACE PORT ASSEMBLY�����������������������������������������������������������������������������������������������������������������������������������������20
H. COMMUNICATIONS�������������������������������������������������������������������������������������������������������������������������������������������������21
I. HEAD LINER��������������������������������������������������������������������������������������������������������������������������������������������������������������22
J. NECK RETAINER AND LOCKING SYSTEM������������������������������������������������������������������������������������������������������������23
K. HELMET FINAL ASSEMBLY������������������������������������������������������������������������������������������������������������������������������������25
L. NECK DAM ASSEMBLY�������������������������������������������������������������������������������������������������������������������������������������������30
VI. APPENDICES�����������������������������������������������������������������������������������������������������������������������������������������������������������������31
A. APPENDIX A: MAIN ASSEMBLIES�������������������������������������������������������������������������������������������������������������������������32
B. APPENDIX B: INNER COMPONENTS��������������������������������������������������������������������������������������������������������������������33
C. APPENDIX C: MANIFOLD BODY ASSEMBLY��������������������������������������������������������������������������������������������������������34
D. APPENDIX D: FREE FLOW VALVE ASSEMBLY����������������������������������������������������������������������������������������������������35
E. APPENDIX E: SECOND STAGE REGULATOR ASSEMBLY����������������������������������������������������������������������������������36
F. APPENDIX F: NOSE CLEARING DEVICE (NCD) ASSEMBLY�������������������������������������������������������������������������������37
G. APPENDIX G: NECK DAM ASSEMBLY������������������������������������������������������������������������������������������������������������������38
H. APPENDIX H: WELDING SHIELD KIT��������������������������������������������������������������������������������������������������������������������39
I. APPENDIX I: WELDING SHIELD ASSEMBLY INSTALLATION INSTRUCTIONS���������������������������������������������������40
J. APPENDIX J: DOUBLE EXHAUST KIT�������������������������������������������������������������������������������������������������������������������41
K. APPENDIX K: DOUBLE EXHAUST KIT INSTALLATION INSTRUCTIONS�����������������������������������������������������������42
L. APPENDIX L: FREE FLOW PLUG INSERT KIT INSTALLATION INSTRUCTIONS�����������������������������������������������44
M. APPENDIX M: CAMERA / LIGHT BRACKET INSTALLATION INSTRUCTIONS���������������������������������������������������46
N. APPENDIX N: TERMINAL BLOCK COMMUNICATIONS KITS������������������������������������������������������������������������������47
O. APPENDIX O: TWIST-ON COMMUNICATIONS KITS���������������������������������������������������������������������������������������������48
P. APPENDIX P: COMMUNICATIONS KIT INSTALLATION INSTRUCTIONS������������������������������������������������������������49
Q. APPENDIX Q: TORQUE SPECIFICATIONS������������������������������������������������������������������������������������������������������������53
R. APPENDIX R: RECOMMENDED CLEANERS AND LUBRICANTS������������������������������������������������������������������������54
S. APPENDIX S: CLEANING AND LUBRICATING������������������������������������������������������������������������������������������������������55
T. APPENDIX T: ANNUAL SERVICE KIT���������������������������������������������������������������������������������������������������������������������56
4 Gorski G2000SS Diving Helmet Technical Manual

VII. CHECKLISTS����������������������������������������������������������������������������������������������������������������������������������������������������������������57
CHECKLIST 1: G2000SS DIVING HELMET DAILY CHECKLIST�������������������������������������������������������������������������������58
CHECKLIST 2: G2000SS DIVING HELMET PRE-DIVE CHECKLIST�������������������������������������������������������������������������62
CHECKLIST 3: G2000SS DIVING HELMET IN-WATER CHECKLIST FOR SUPERVISOR���������������������������������������65
CHECKLIST 4: G2000SS DIVING HELMET POST-DIVE CHECKLIST�����������������������������������������������������������������������67
CHECKLIST 5: G2000SS DIVING HELMET MONTHLY INSPECTION AND MAINTENANCE CHECKLIST�������������70
CHECKLIST 6: G2000SS DIVING HELMET ANNUAL INSPECTION AND MAINTENANCE CHECKLIST����������������75
VIII. SPARE PARTS CROSS-REFERENCE LIST���������������������������������������������������������������������������������������������������������������84
IX. G2000SS DIVING HELMET ACCESSORIES����������������������������������������������������������������������������������������������������������������87
X. MAINTENANCE NOTES�������������������������������������������������������������������������������������������������������������������������������������������������88
5

I. SAFETY INFORMATION
THE G2000SS DIVING HELMET SHOULD BE USED BY CERTIFIED AND PROPERLY TRAINED
DIVERS ONLY.

Note: Recommended air supply pressure 140 - 170 PSI Over Bottom Pressure (OBP).

WARNING:
• Supply pressure below 140 PSI OBP may lead to CO2 buildup inside the
helmet.
• Supply pressure above 200 PSI OBP will cause the regulator to free flow.

WARNING: The G2000SS diving helmet is not cleaned or lubricated for


oxygen service.

CONTAMINATED WATER DIVING

CAUTION: The helmet should not be used for contaminated water diving (CWD)
when only a single exhaust is fitted. A double exhaust adapter kit is available
for CWD. When used for CWD with double exhaust fitted, the free flow valve
must be open and properly adjusted at all times throughout the dive, as posi-
tive pressure inside helmet must be maintained.

II. WARRANTY INFORMATION


The manufacturer warrants every new helmet to be free from defects in workmanship for a
period of ninety (90) days 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 rubber parts, 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 G2000SS Diving Helmet Technical Manual.
6 Gorski G2000SS Diving Helmet Technical Manual

III. HELMET SET-UP AND OPERATION


SET-UP PROCEDURES
Testing the Check Valves : The helmet is equipped with two check valves, one for main air and
the other for emergency air. Each check valve should be checked prior to connecting a hose. To
check each check valve, the free flow valve must be open and air must be pulled from the check
valve to verify that it is closed. The hoses can be attached only after verifying that the check
valves are properly functioning.
Testing the Emergency Gas Supply (EGS) : After the diver has verified a proper seal of the helmet
on his head and the main air is bled from the hose, the diver must turn his emergency (bailout)
cylinder valve on and use the bailout regulator to breathe inside the helmet. The emergency
cylinder valve must then be shut, leaving the hose pressurized. The EGS must ALWAYS be turned
“off” at the cylinder valve while diving.

CHECKLISTS
The following checklists are provided to assist all users and technicians:
User:
• Daily Checklist�������������������������������������������������������������������������������������������������� Section VII
• Pre-Dive Checklist�������������������������������������������������������������������������������������������� Section VII
• In-Water Checklist for Supervisor��������������������������������������������������������������������� Section VII
• Post-Dive Checklist������������������������������������������������������������������������������������������� Section VII
• Technician:
• Monthly Inspection & Maintenance Checklist��������������������������������������������������� Section VII
• Annual Inspection & Maintenance Checklist����������������������������������������������������� Section VII

GAS SUPPLY PRESSURES


Minimum gas supply pressures are calculated by multiplying the depth of dive by 0.445 psi then
adding the required over-bottom for depth.
Required over-bottom pressures for depth:
Depth OBP
0 – 60 fsw (0 - 18.3 msw) 90 psig (6.2 bar)
61 – 100 fsw (18.6 – 30.5 msw) 115 psig (7.9 bar)
101 – 132 fsw (30.8 – 40.2 msw) 135 psig (9.3 bar)
133 – 165 fsw (40.6 – 50.3 msw) 165 psig (11.4 bar)
166 – 220 fsw (50.5 – 67.1 msw) 200 psig (13.8 bar)

Note:
• If the above OBP cannot be supplied, the diver must reduce his workload to
avoid exhaustion.
• The second stage regulator and manifold have a maximum design pressure of
225 psig (15.5 bar) over-bottom.
7

IV. HELMET MAINTENANCE & PARTS LISTS

IMPORTANT NOTES
This manual provides factory prescribed procedures for the correct service and repair of the G2000SS
diving helmet. It is strongly recommended that all repairs are completed in accordance with this
manual.

The procedures outlined within this manual 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 manual, contact Aqua Lung
to speak directly with a Technical Advisor before proceeding any further.

SCHEDULED SERVICE

1. The G2000SS 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 400108) contains all parts that are replaced annually. See Appendix
T for details of this kit.
LUBRICATION

Helmets used for air diving or diving with gas containing oxygen percentages less than 40% may be
lubricated with Christo-Lube® MCG 111, Dow Corning® 111 or equivalent.

All o-rings must be lubricated prior to assembly.

CAUTION: DO NOT lubricate diaphragms or one-way valves. Lubricating attracts dirt


and debris, this may cause the item to malfunction.

COMPONENT INTERCHANGEABILITY
The G2000SS diving helmet is designed specifically so that all new or modified assemblies are
interchangeable with, and may be retrofitted to, all existing helmets. This enhances product support.
Certain step-by-step procedures in this manual show older assemblies – this demonstrates component
interchangeability and makes no difference to helmet performance or functionality.
8 Gorski G2000SS Diving Helmet Technical Manual

HELMET MAINTENANCE & PARTS LISTS (continued)


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 G2000SS 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.

PART NUMBERS
FOR PART NUMBERS REFER TO THE G2000SS DIVING HELMET PARTS LIST IN THE
APPENDICES LOCATED AT THE BACK OF THE MANUAL.

Main Assemblies��������������������������������������������������������������������������������������������������������� Appendix A


Inner Components������������������������������������������������������������������������������������������������������ Appendix B
Manifold Body Assembly��������������������������������������������������������������������������������������������Appendix C
Free Flow Valve Assembly������������������������������������������������������������������������������������������Appendix D
Second Stage Regulator Assembly���������������������������������������������������������������������������� Appendix E
Nose Clearing Device (NCD) Assembly��������������������������������������������������������������������� Appendix F
Neck Dam Assembly��������������������������������������������������������������������������������������������������Appendix G
Welding Shield Kit�������������������������������������������������������������������������������������������������������Appendix H
Double Exhaust Kit���������������������������������������������������������������������������������������������������� Appendix J
Terminal Block Communications Kits�������������������������������������������������������������������������Appendix N
Twist-On Communications Kits�����������������������������������������������������������������������������������Appendix O
9

V. STEP-BY-STEP ASSEMBLY INSTRUCTIONS

NOTES ON DISASSEMBLY AND ASSEMBLY


1. Disassembly procedures are the reverse of assembly.

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

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

HELMET SUB-ASSEMBLIES IN THIS SECTION

• Second Stage Regulator • Communications


• Free Flow / Exhaust Valve • Head Liner
• Manifold • Neck Retainer and Locking System
• Defogger • Helmet Final Assembly
• Oral-Nasal Mask • Neck Dam Assembly
• Nose Clearing Device (NCD) • Quad Ring Installation
• Face Port Assembly

TOOLS REQUIRED FOR ANNUAL MAINTENANCE

3/8" Nut Driver 5/16" Flat Blade Screwdriver (Regulator Adjust)


7/16" Nut Driver Phillips #3 Screwdriver
3/16" Allen/Hex Key 15/16" Deep Socket and Driver
1/4" Allen/Hex Key 11/16" Socket and Driver
5/8" Flat OE Low Profile / Slim Wrench 7/8" Deep Socket and Driver
11/16" Flat OE Low Profile / Slim Wrench Torque Screwdriver (20 - 140 inch pounds)
O-Ring Tool (Brass or plastic) Torque Wrench (10 - 40 foot pounds)
3/8" Flat Blade Screwdriver
10 Gorski G2000SS Diving Helmet Technical Manual

SECOND STAGE REGULATOR

Step 1: Place diaphragm (65) into Step 2: Diaphragm (65) in the Step 3: Install the purge button
diaphragm housing (66). DO NOT diaphragm housing (66). (63a) onto the diaphragm cover
lubricate the diaphragm. (63).

Step 4: Purge button (63a) installed Step 5: Install the diaphragm Step 6: Slightly compress the
in diaphragm cover (63). cover (63) onto the diaphragm diaphragm cover (63) and install
housing (66). the cover snap ring (64). NOTE:
over-compression will cause
damage to the cover.

Step 7: Ensure that the cover Step 8: Install exhaust flapper Step 9: Using snap ring pliers
snap ring (64) sits securely in the valve (55) on rear of the dia- install the flapper valve snap
inside groove. phragm housing (66). DO NOT ring (56).
lubricate the flapper valve.

Step 10: Lubricate and install o-ring Step 11: Diaphragm housing
(54) on outside of the diaphragm complete.
housing (66).
11

SECOND STAGE REGULATOR (continued)

Step 12: Lubricate and install small Step 13: O-ring (67) installed on Step 14: Lubricate and install
o-ring (67) on main body (68). main body (68). small o-ring (67) on LP valve
assembly (69).

Step 15: O-ring (67) installed on Step 16: Second stage regulator Step 17: Set the valve, rotate
LP valve assembly (69). components ready for assembly. sleeve so right edge of cut aligns
with center line of lever.

Step 18: Install LP valve assembly Step 19: Install connecting ring Step 20: Connecting ring (70)
(69) into main body (68). (70) and tighten by hand. securely installed.

Step 21: Use A 5/16" flat blade Step 22: Hold in vertical position. Step 23: Adjust until lever end
screwdriver for adjustment. is level with main body (68)
top edge.
12 Gorski G2000SS Diving Helmet Technical Manual

SECOND STAGE REGULATOR (continued)

Step 24: Insert lever into dia- Step 25: Diaphragm housing
phragm tube, tighten by hand. installed on main body.

Note: Maintenance procedures for the low pressure valve - circled in the
photo below - are contained in the separate excerpt from Poseidon Cyclone
5000 Regulator Manual.
13

FREE FLOW / EXHAUST VALVE

Step 1: Breakdown of free flow/ Step 2: Install small o-ring (53) Step 3: O-ring (53) installed on
exhaust valve parts. onto valve body (52). valve body (52).

Step 4: Install o-ring (54) onto the Step 5: Put exhaust flapper valve Step 6: Flapper valve (55) in-
valve body (52) groove. (55) on the valve body (52). stalled on valve body (52).

Step 7: Install snap ring (56) in the Step 8: Snap ring (56) installed. Step 9: Place valve seat (57) into
groove on the valve body (52). the valve body (52).
14 Gorski G2000SS Diving Helmet Technical Manual

FREE FLOW / EXHAUST VALVE (continued)

Step 10: Thread in the valve seat Step 11: Place two copper wash- Step 12: Place o-ring (60) into
(57) with valve stem (59). ers (58) into the valve body (52). the bonnet valve (62).

Step 13: Place Teflon ring (61) Step 14: Place the stem (59) Step 15: Place the valve bonnet
over the o-ring into the valve into the valve body (52) over the assembly over the stem (59) into
bonnet (62). seat (57). the valve body (52).

Step 16: Thread the valve bonnet Step 17: Tighten the valve bonnet Step 18: Free flow/exhaust valve
(62) into the valve body (52). (62) with a 11/16" socket to 35 ft.lbs assembled.
(47 Nm).
15

MANIFOLD

Step 1: Break down of manifold Step 2: Insert screen (40) into the Step 3: Line up screen (40) with
assembly. manifold body (37). Failure to in- the end of threads.
stall may cause debris to block
the flow of gas to the diver.

Step 4: Install o-ring (39) onto man- Step 5: Tighten the manifold plug Step 6: Install o-ring (27) onto
ifold plug (38). Screw manifold plug (38) with a 7/8" socket to 90 in.lbs port plug (47). Using a 3/16" hex
(38) to the manifold body (37). (10 Nm). key, screw the port plug (47) to
the manifold body (37).

Step 7: Tighten port plug (47) with Step 8: Screw check valve (48) Step 9: Screw check valve (48)
a 3/16" hex key until to 45 in.lbs (with Teflon tape) into the first (with Teflon tape) into the 2nd
(5 Nm). port of the manifold body (37). port of the manifold body (37).

Step 10: Screw scuba fitting (49) Step 11: Screw hose fitting (49) Step 12: Tighten both check valve
(with Teflon tape) to the first check (with Teflon tape) to the 2nd check assemblies to the manifold body
valve (48) and tighten firmly. valve (48) and tighten firmly. (37) with an 7/8" socket. Replace
caps (51).
16 Gorski G2000SS Diving Helmet Technical Manual

DEFOGGER

Step 1: Two parts of defogger, low- Step 2: Insert lower unit over the Step 3: Push lower unit until it
er and upper unit. free flow/exhaust valve body. stops.

Step 4: Line up upper unit with the Step 5: Slide upper unit over the
lower unit. bracket of the lower unit.
17

ORAL-NASAL MASK
CAUTION: The head liner of the oral-nasal mask must be used at all
times when diving. The head liner ensures that the oral-nasal mask
maintains a good fit on the diver’s face and reduces dead space in the
helmet, this helps prevent CO2 build up.

Step 1: Oral-Nasal mask (32) with Step 2: Line up and install inhala- Step 3: Inhalation valve assem-
inhalation valve (34) and inhala- tion valve (34) in the inhalation valve bly for oral-nasal mask (32).
tion valve housing (33). housing (33). DO NOT lubricate
the valve.

Step 4: Insert inhalation valve as- Step 5: Outside view of the Step 6: Insert second stage reg-
sembly into the pocket on the left correctly installed inhalation ulator into the helmet shell (1).
side of the oral-nasal mask (32). valve (34) and inhalation valve
housing (33).

Note: Inhalation valve must be installed on the inside of the oral-nasal mask. If
reversed it could cause serious problems including injury or death of the diver.

Step 7: Install regulator cover (17) Step 8: Install microphone (35) in Step 9: Point microphone wire
and tighten all screws (15) to 45 the right pocket of the oral-nasal downwards..
in.lbs (5 Nm) with a Phillips #3 mask (32).
screwdriver.
18 Gorski G2000SS Diving Helmet Technical Manual

ORAL-NASAL MASK (continued)

Step 10: Install oral-nasal mask (32) Step 11: Install nose clearing de- Step 12: Secure NCD knob (71)
onto the regulator mouthpiece. vice (73) into the helmet shell (1). on the NCD shaft (73). Ensure
that it is snug.

Step 13: Always check before div- Step 14: Inside view of installed
ing to ensure that no threads are oral-nasal mask assembly.
visible in order to prevent loosing
the knob (71).
19

NOSE-CLEARING DEVICE (NCD)

Step 1: Breakdown of nose clear- Step 2: Install two o-rings (72) into Step 3: O-rings (72) installed.
ing device parts. the grooves using o-ring pick.

Step 4: Place neoprene pad (75) over Step 5: Fold over and press the
nose cleaning device (73) as shown. pad ends together.
20 Gorski G2000SS Diving Helmet Technical Manual

FACE PORT ASSEMBLY

Step 1: Place o-ring (18) in the Step 2: O-ring (18) installed in Step 3: Place face port (19) into
port groove. port groove. the helmet shell (1).

Step 4: Face port (19) installed. Step 5: Place port retainer (20) over Step 6: Install bottom screw (21)
face port (19) and line up holes. in the port retainer (20) with a
Phillips #3 screwdriver.

Step 7: Install top screw (21) in Step 8: Install the remaining Step 9: Tighten all screws (21) to
port retainer (20), all holes should screws (21). 45 in.lbs (5 Nm) with a Phillips #3
be lined up. screwdriver.
21

COMMUNICATIONS
Note: The communications system is designed and built by Ocean
Technology Systems (OTS) specifically for the G2000SS Diving Helmet.

Comm Bulkhead
4-Wire

Comm Post
2-Wire

Step 1: Communications bulkhead Step 2: Breakdown of communica- Step 3: Securely install all termi-
(23) with blank cap for use with tions assembly parts. nals to the internal posts using a
4-wire communications. Commu- 3/8" nut driver.
nication post assembly (22) for
use with 2 wire communications.

Step 4: Install microphone (35) in Step 5: Microphone (35) installed Step 6: Install left speaker (30)
the right pocket of the oral-nasal in oral-nasal mask (32). and right speaker (31) with the
mask (32). long wire on the left side.

Step 7: Place left speaker (30) in Step 8: Place right speaker (31) Step 9: Communications system
left pocket of head liner. in right pocket of head liner. installed.

Note:
• The helmet is fitted with a 2-wire communications system, using communication
posts (22) as standard.
• The helmet may also be fitted with a 4-wire system using the communication
bulkhead (23). The bulkhead is a standard feature (introduced in 2012) and, if
not used, is fitted with a blank plug.
22 Gorski G2000SS Diving Helmet Technical Manual

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

Step 1: Cut Velcro tape into 4 piec- Step 2: Round off the corners on Step 3: Stick Velcro tabs onto
es, approximately 2 in x 1 in each. 2 pieces of Velcro as shown. both front sides of the helmet
shell (1).

Step 4: Stick Velcro tabs onto both Step 5: Head liner. Step 6: Line up head liner as
rear sides of the helmet shell (1). shown.

Step 7: Place left speaker (30) in Step 8: Place right speaker (31) Step 9: Head liner installed into
left pocket of head liner. in right pocket of head liner. helmet shell (1). (No oral-nasal
mask fitted).

Note: The head liner may be washed by hand or machine. Recommended Velcro:
Industrial strength, sticky back tape, waterproof.
23

NECK RETAINER AND LOCKING SYSTEM


Note: This version (MOD1) of the neck retainer and locking system was introduced in
2011. For the original version refer to previous editions of the helmet Technical Manual.

Step 1: Breakdown of locking sys- Step 2: Insert latch (left 8a or Step 3: Latch inserted in latch
tem parts. right 8b) into corresponding latch base.
Note: There are left and right base (left 2a or right 2b).
latch catch assemblies

Step 4: Fit latch spring (9) over Step 5: Fit latch spring washer (10) Step 6: Insert manifold hex screw
shaft of latch (Left 8a or Right 8b). onto manifold hex screw (11). (11) and washer (10) into shaft of
latch (Left 8a or Right 8b).

Step 7: Tighten manifold hex Step 8: Fit assembled latch base Step 9: Fit latch spring washer
screw (11) using a 3/16" hex key (left 2a or right 2b) onto correct (3) onto latch screw (4).
to 80 in.lbs (9 Nm). side of helmet shell (1).
24 Gorski G2000SS Diving Helmet Technical Manual

NECK RETAINER AND LOCKING SYSTEM (continued)


Note: This version (MOD1) of the neck retainer and locking system was introduced in
2011. For the original version refer to previous editions of the helmet Technical Manual.

Step 10: Insert latch screw (4) and Step 11: Tighten latch screw (4) Step 12: Repeat the procedure
latch spring washer (3) through using a 1/4" hex key to 140 in.lbs for the other latch.
helmet shell (1) into latch base (16 Nm).
assembly.

Step 13: Test the operation of each Step 14: Check condition of neck Step 15: Place the neck retainer
latch assembly. retainer (5). (5) to the hinge at rear of helmet
shell (1). Insert the neck retain-
er bolt (6) and secure with neck
retainer nut (7). Use a 3/16" hex
key to hold the bolt and 7/16" nut
driver to hold the nut. Tighten
until the nut touches the hinge.
Adjust as required.
Note: Ensure that neck retainer
moves freely.

Step 16: Ensure that neck retainer and locking


system mates correctly.
25

HELMET FINAL ASSEMBLY

Step 1: Installed free flow valve Step 2: Free flow valve in place. Step 3: Inside view of free flow
assembly. valve.

Step 4: Install second stage on Step 5: Inside view of second Step 6: Push mouthpiece
opposite side. stage. straight up.

Step 7: Place o-ring (27) on swage- Step 8: Screw connector into Step 9: Tighten swagelock con-
lock connector (26). free flow valve body (52). nector (26) into free flow valve
body (52) using 5/8" OE wrench
to 45 in.lbs (5 Nm).
26 Gorski G2000SS Diving Helmet Technical Manual

HELMET FINAL ASSEMBLY (continued)

Step 10: Airway assembly (24). Step11: Stick open end of air- Step 12: Press airway assembly
way assembly into swagelock (24) inside the helmet shell (1).
connector (26).

Step 13: Press bracket end of the Step 14: Manifold connecting Step 15: Place o-rings (42) in
airway assembly (24) to the back insert and o-rings. both grooves of the manifold
wall of the helmet shell (1). insert (41).

Step 16: Manifold connecting Step 17: Place manifold insert Step 18: Manifold insert installed.
insert assembled. (41) through the wall of the hel-
met shell (1) into the airway
bracket socket.
27

HELMET FINAL ASSEMBLY (continued)

Step 19: Tighten swagelock nut Step 20: Place regulator cover Step 21: Use a Phillips #3 screw-
onto airway assembly (24) hand (17) as shown. driver to put the first exhaust
tight, then an additional 1¼ of a valve cover screw (15) in place
turn with a 11/16" OE wrench. & line up all holes.

Step 22: Secure the regulator cov- Step 23: Regulator cover (17) Step 24: Place exhaust valve
er (17) in place with all 5 screws installed. cover (16) in place.
and tighten using a Phillips #3
screwdriver to 45 in.lbs (5 Nm).

Step 25: Use a Phillips #3 screw- Step 26: Secure the exhaust Step 27: Free flow valve knob
driver to put the first screw (15) in valve cover (16) in place with parts.
place & line up all holes. all 5 screws and tighten using
a Phillips #3 screwdriver to 45
in.lbs (5 Nm).
28 Gorski G2000SS Diving Helmet Technical Manual

HELMET FINAL ASSEMBLY (continued)

Step 28: Place the free flow knob Step 29: Fit the spring (13) to the Step 30: Put the knob nut (12)
(14) over the valve stem (59). free flow knob (14). inside the knob (14).

Step 31: Tighten the knob nut (12) Step 32: Knob installed. Step 33: Place the manifold
to the valve stem (59) with a 3/8" gasket (45) over the back side
flat blade screwdriver. of helmet shell (1) and line up
the holes.

Short
Screw
Long
Screw

Step 34: Line up assembled man- Step 35: Use longer manifold Step 36: Tighten the longer man-
ifold body (37) with the manifold hex screws (11) on left side and ifold hex screws (11) onto inner
insert (41) and holes. short manifold hex screws (43) airway bracket using a 3/16" hex
on right side. key to 80 in.lbs (9 Nm).
29

HELMET FINAL ASSEMBLY (continued)

Step 37: Tighten short hex screw Step 38: Tighten short hex screw Step 39: Manifold installed.
(43) onto the bottom of helmet using (43) onto the top of helmet using a
a 3/16" hex key to 80 in.lbs (9 Nm). 3/16" hex key to 80 in.lbs (9 Nm).

Step 40: Line up neck retainer (5) Step 41: Put the neck retainer nut Step 42: Use a 3/16" hex key to
with the hinge and insert the neck (7) on the neck retainer bolt (6). hold the bolt and 7/16" nut driver
retainer bolt (6). to hold the nut. Tighten until the
nut touches the hinge. Adjust as
required.
Note: Ensure that neck retainer
moves freely.

ORAL / NASAL ASSEMBLY

Step 43: Install nose clearing de- Step 44: Screw NCD knob (71) Step 45: NCD installed outside
vice (73) through the inside of hel- into the nose clearing device (73). view (No oral-nasal mask).
met shell (1).
30 Gorski G2000SS Diving Helmet Technical Manual

NECK DAM ASSEMBLY

Step 1: Place front portion of neck Step 2: Use neck retainer (5) to Step 3: Install neck dam.
dam into the front of the helmet. push the back side of the neck
dam in place.

Note: The above photographs show the old, pre-2011 neck retainer. The current neck
retainer MOD1 with neck dam in place, is shown below.

Step 1: Neck retainer MOD1. Step 2: Neck retainer MOD1 with


right latch catch open.

Quad Ring Installation

Step 1: Lightly lubricate quad ring Step 2: Quad ring (76) installed.
(76) and install in groove of upper
neck ring (77).
31

VI. APPENDICES
IMPORTANT NOTE

Note: All Gorski part numbers have been assigned Aqua Lung (AQA) part numbers
– a cross-reference list is at the back of this manual.

Appendix A Main Assemblies


Appendix B Inner Components
Appendix C Manifold Body Assembly
Appendix D Free Flow Valve Assembly
Appendix E Second Stage Regulator Assembly
Appendix F Nose Clearing Device (NCD) Assembly
Appendix G Neck Dam Assembly
Appendix H Welding Shield Kit
Appendix I Welding Shield Assembly Installation Instructions
Appendix J Double Exhaust Kit
Appendix K Double Exhaust Kit Installation Instructions
Appendix L Free Flow Plug Insert Kit Installation Instructions
Appendix M Camera / Light Bracket Installation Instructions
Appendix N Terminal Block Communications Kits
Appendix O Twist-On Communications Kits
Appendix P Communications Kit Installation Instructions
Appendix Q Torque Specifications
Appendix R Recommended Cleaners and Lubricants
Appendix S Cleaning and Lubricating
Appendix T Annual Service Kit
32 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX A – MAIN ASSEMBLIES


25 ft.lbs SS Blank Plug
(34 Nm) 90 in.lbs
INNER (10 Nm) INNER COMPONENTS
COMPONENTS 140 in.lbs
SEE APPENDIX B SEE APPENDIX B
4
8A (16 Nm)

MANIFOLD BODY ASM 23 23B 1 3


SEE APPENDIX C
2A
22 39 10 15
9
17
11

SECOND STAGE ASM


SEE APPENDIX E

NOSE CLEARING
DEVICE ASM
SEE APPENDIX F
6
NECK DAM ASM
SEE APPENDIX G
FREE FLOW ASM
SEE APPENDIX D

7
2B
8B 11
9
10
16
5 80 in.lbs 15
(9 Nm) 14
13
12
45 in.lbs
(5 Nm)
18
19
20 21 45 in.lbs
(5 Nm)

REV. E ~04/22/11

ITEM QTY ITEM QTY


AQA P/N GORSKI P/N DESCRIPTION AQA P/N GORSKI P/N DESCRIPTION
NO NO
1 1 400001 1SS-0001 SHELL, HELMET 13 1 400007 1SS-0013 SPRING, KNOB (5 PK)
2A 1 400116 1SS-0101 BASE, LATCH, LEFT 14 1 400008 1SS-0014 KNOB, FREE FLOW
2B 1 400117 1SS-0102 BASE, LATCH, RIGHT 15 10 400009 1SS-0015 SCREW, EXHAUST VALVE COVER (5 PK)
3 2 400120 1SS-0003 WASHER, LATCH SPRING (2 PK) 16 1 400010 1SS-0016 COVER, EXHAUST VALVE
4 2 400113 1SS-0099 SCREW, LATCH 5/16" - 18 X 3/4" LONG 17 1 400011 1SS-0017 COVER, REGULATOR
5 1 400114 1SS-0100 RETAINER, NECK, MOD 1 18 1 400012 1SS-0018 O-RING, FACE PORT
6 1 400003 1SS-0006 BOLT, NECK RETAINER (5 PK) 19 1 400013 1SS-0019 PORT, FACE
7 1 400004 1SS-0007 NUT, NECK RETAINER (5 PK) 20 1 400014 1SS-0020 RETAINER, PORT
8A 1 400118 1SS-0103 LATCH, LEFT 21 12 400015 1SS-0021 SCREW, RETAINER PORT (5 PK)
8B 1 400119 1SS-0104 LATCH, RIGHT 22 2 400016 1SS-0022 POST, COMMUNICATION ASSEMBLY
9 2 400005 1SS-0009 SPRING, LATCH (5 PK) BULKHEAD, COMM W/ SS BLANK PLUG
23 1 400017 1SS-0023
ASSY
10 2 400120 1SS-0105 WASHER, LATCH SPRING (2 PK)
39 1 400031 1SS-0039 O-RING, MANIFOLD PLUG (10 PK)
11 2 400036 1SS-0044 SCREW, HEX, MANIFOLD (5 PK) CAP & PLASTIC FERRULES,
23B 1 400122 1SS-0108
BULKHEAD ASSY
12 1 400006 1SS-0012 NUT, KNOB (5 PK)

Part numbers in BOLD ITALICS indicate standard overhaul replacement part.


33

APPENDIX B – INNER COMPONENTS

30

32

28

31 33
34

24

35
26
45 in.lbs
(5 Nm) 29
27

REV. D ~ 05/10/06

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
24 1 400138 N/A AIRWAY ASSEMBLY
26 1 400021 1SS-0026 SWAGELOCK CONNECTOR
27 1 400022 1SS-0027 O-RING, SWAGELOCK CONN & PORT PLUG (10 PK)
28 1 400023 1SS-0028 TRAIN, DEFOGGER
29 1 400024 1SS-0029 BARREL, FREE FLOW
30 1 400129 1SS-0030 SPEAKER LEFT
31 1 400130 1SS-0031 SPEAKER RIGHT
32 1 400025 1SS-0032 MASK, ORAL NASAL
33 1 400026 1SS-0033 HOUSING, INHALATION VALVE
34 1 400027 1SS-0034 VALVE, INHALATION
35 1 400131 1SS-0035 MICROPHONE
N/S 1 400028 1SS-0036 HEAD LINER

Part numbers in BOLD ITALICS indicate standard overhaul replacement part.


34 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX C – MANIFOLD BODY ASSEMBLY


80 in.lbs
80 in.lbs 11 (9 Nm)
(9 Nm) 11
90 in.lbs
(10 Nm)
43
41
43 38
42
42
45

39

37

40

27
47
48

45 in.lbs 50
(5 Nm)
48
51

49

51

Rev. C ~ 05/10/06

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
37 1 400029 1SS-0037 BODY, MANIFOLD
38 1 400030 1SS-0038 PLUG, MANIFOLD (LARGE)
39 1 400031 1SS-0039 O-RING, MANIFOLD PLUG (10 PK)
40 1 400032 1SS-0040 SCREEN
41 1 400033 1SS-0041 INSERT, MANIFOLD
42 2 400034 1SS-0042 O-RING, MANIFOLD CONNECTOR (10 PK)
43 2 400035 1SS-0043 SCREW, HEX, MANIFOLD (5 PK)
11 2 400036 1SS-0044 SCREW, HEX, MANIFOLD (5 PK)
45 1 400037 1SS-0045 GASKET, MANIFOLD
27 1 400022 1SS-0027 O-RING , SWAGELOCK CONN & PORT PLUG (10 PK)
47 1 400039 1SS-0047 PORT PLUG
48 2 400040 1SS-0048 VALVE, CHECK
49 1 400041 1SS-0049 FITTING, SCUBA
50 1 400042 1SS-0050 FITTING, HOSE
51 2 400043 1SS-0051 CAP, FITTING, BRASS

Part numbers in BOLD ITALICS indicate standard overhaul replacement part.


35

APPENDIX D – FREE FLOW VALVE ASSEMBLY

35 ft.lbs
(47 Nm)

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
52 1 400044 1SS-0052 BODY, FREE FLOW EXHAUST VALVE
53 1 400045 1SS-0053 O-RING, EXHAUST, SMALL (10 PK)
54 1 400046 1SS-0054 O-RING, EXHAUST, LARGE (10 PK)
55 1 400047 1SS-0055 VALVE, FLAPPER EXHAUST
56 1 400048 1SS-0056 RING, SNAP FLAPPER VALVE
57 1 400049 1SS-0057 SEAT, FREE FLOW VALVE
58 2 400050 1SS-0058 WASHER, COPPER (5 PK)
59 1 400051 1SS-0059 STEM, FREE FLOW VALVE
60 1 400052 1SS-0060 O-RING, STEM FREE FLOW VALVE (10 PK)
61 1 400053 1SS-0061 WASHER, TEFLON (5 PK)
62 1 400054 1SS-0062 VALVE, FREE FLOW BONNET

Part numbers in BOLD ITALICS indicate standard overhaul replacement part.


36 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX E – SECOND STAGE REGULATOR ASSEMBLY

70
69

67

68

67
56

55

66

54

65

64
63a G2000SS, INC.
63
REV. B ~ 05/10/06 SHEET 5 OF 7

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
63 1 400055 1SS-0063 COVER, DIAPHRAGM
63a 1 400056 1SS-0063 BUTTON, PURGE (5 PK)
64 1 400057 1SS-0064 RING, SNAP, COVER (5 PK)
65 1 400058 1SS-0065 DIAPHRAGM, SECOND STAGE
66 1 400059 1SS-0066 HOUSING, SECOND STAGE DIAPHRAGM
67 2 400060 1SS-0067 O-RING, REGULATOR BODY, SMALL (10 PK)
68 1 400061 1SS-0068 BODY, SECOND STAGE MAIN
69 1 400062 1SS-0069 ASSEMBLY, VALVE
70 1 400072 1SS-0070 RING, CONNECTING
54 1 400046 1SS-0054 O-RING, EXHAUST, LARGE (10 PK)
55 1 400047 1SS-0055 VALVE, FLAPPER EXHAUST
56 1 400048 1SS-0056 RING, SNAP FLAPPER VALVE

Part numbers in BOLD ITALICS indicate standard overhaul replacement part.


37

APPENDIX F – NOSE CLEARING DEVICE (NCD) :ASSEMBLY

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
71 1 400073 1SS-0071 KNOB, NCD
72 2 400074 1SS-0072 O-RING, NOSE CLEARING DEVICE (NCD) (10 PK)
73 1 400140 N/A NOSE CLEARING DEVICE (WELDED)
75 1 400077 1SS-0075 NOSE PAD, NEOPRENE (5 PK)

Part numbers in BOLD ITALICS indicate standard overhaul replacement part.


38 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX G – NECK DAM ASSEMBLY

76

77

78
83

82 79

81
80
20 in.lbs
(2 Nm) 20 in.lbs
84 (2 Nm)

G2000SS, INC.
REV. B ~ 05/11/06 SHEET 7 OF 7

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
76 1 400078 1SS-0076 RING, QUAD
77 1 400079 1SS-0077 RING, NECK UPPER
78 1 400080 1SS-0078 SEAL, NECK
79 1 400081 1SS-0079 RING, NECK BOTTOM
80 18 400082 1SS-0080 SCREW, NECK RING LOWER (5 PK)
81 2 400083 1SS-0081 SCREW, BUCKLE STRAP (5 PK)
82 2 400084 1SS-0082 BUSHING, BUCKLE STRAP (5 PK)
83 2 400085 1SS-0083 BUCKLE, STRAP
84 1 400086 1SS-0084 STRAP, NYLON W/ D-RINGS
39

APPENDIX H – WELDING SHIELD KIT


45 in.lbs 88 87
92 (5 Nm)
90
91 86

45 in.lbs
(5 Nm)

80 in.lbs 93 21
(9 Nm) 87

43

91 90

92

43 45 in.lbs
(5 Nm)

85

G2000SS, INC.
REV. A~06/03/04 WELD SHIELD ACCESSORIES

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
85 1 400087 1SS-0085 BODY, WELDING SHELL (SHIELD)
86 1 400088 1SS-0086 LENS, WELDING
87 2 400089 1SS-0087 BRACKET, LENS HOLDING (2 PK)
88 1 400090 1SS-0088 GASKET, WELDING LENS
43 2 400035 1SS-0043 SCREW, HEX, MANIFOLD (5 PK)
90 2 400092 1SS-0090 HINGE, BLOCK WELDING LENS (2 PK)
91 2 400093 1SS-0091 SCREW, HINGE BLOCK MOUNTING (5 PK)
92 2 400094 1SS-0092 SCREW, HINGE (5 PK)
93 1 400095 1SS-0093 SHIELD, WELDING SPRING
21 1 400015 1SS-0021 SCREW, RETAINER PORT (5 PK)
40 Gorski G2000SS Diving Helmet Technical Manual

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 / Gorski to
speak directly with a Technical Advisor before proceeding any further.

KIT CONTENTS

AQA Part No. Gorski Part No. Item Description Qty per Kit
400087 1SS-0085 Body, Welding Shell (Shield) 1
400088 1SS-0086 Lens, Welding 1
400089 1SS-0087 Bracket, Lens Holding 2
400090 1SS-0088 Gasket, Welding Lens 1
400035 1SS-0043 Screw, Hex, Manifold 2
400092 1SS-0090 Hinge Block, Welding Lens 2
400093 1SS-0091 Screw, Hinge Block Mounting 2
400094 1SS-0092 Screw, Hinge 2
400095 1SS-0093 Shield, Welding Spring 1
400015 1SS-0021 Screw, Retainer Port 1

Step-by-Step Assembly Instructions

Step 1: Use a Phillips # 3 screwdriver Step 2: Install shield welding Step 3: Line up welding lens (86).
to remove three retainer port screws spring (93). Note: Hinge blocks (90)
(21) from top of helmet retainer port
and hinge screws (92)
(20).
pre-mounted to shield.

Step 4: Secure and tighten left and Step 5: Secure and tighten left Step 6: Confirm welding shield
right hinge block mounting screws and right hinge screws (92) to 45 opens and closes correctly.
(91) to 45 in.lbs (5 Nm). in.lbs (5 Nm).
41

APPENDIX J– DOUBLE EXHAUST KIT

95

96

97

55

16

REV. A~05/11/06 21

45 in.lbs
(5 Nm)

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
95 1 400097 1SS-0095 BUSHING, DUAL EXHAUST
96 1 400098 1SS-0096 SEAT, DUAL EXHAUST
97 5 400099 1SS-0097 RING, SPACER (5 PK)
21 5 400015 1SS-0021 SCREW, RETAINER PORT (5 PK)
55 1 400047 1SS-0055 VALVE, FLAPPER EXHAUST
42 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX K
DOUBLE EXHAUST KIT (P/N 400111)
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 / Gorski to
speak directly with a Technical Advisor before proceeding any further.

KIT CONTENTS

AQA Part No. Gorski Part No. Item Description Qty per Kit
400097 1SS-0095 Bushing, Dual Exhaust 1
400098 1SS-0096 Seat, Dual Exhaust 1
400099 1SS-0097 Ring, Spacer 5
400015 1SS-0021 Screw, Retainer Port 5
400047 1SS-0055 Valve, Flapper Exhaust 1

Step-by-Step Assembly Instructions

Step 1: Unscrew knob nut (12) Step 2: Remove free flow knob Step 3: Unscrew exhaust valve
with a 3/8" flat blade screwdriver. (14), knob spring (13) and knob cover screws (15) using a Phillips
nut (12). #3 screwdriver.

Step 4: Remove exhaust valve Step 5: Parts breakdown for Step 6: Place dual exhaust
cover (16). double exhaust conversion. bushing (95) over free flow valve
stem (59).
43

DOUBLE EXHAUST KIT INSTALLATION INSTRUCTIONS (continued)

Step 7: Dual exhaust bushing Step 8: Place dual exhaust Step 9: Place flapper exhaust
(95) installed onto free flow valve seat (96) over the dual exhaust valve (55) onto the dual exhaust
stem (59). bushing (95). seat (96). DO NOT LUBRICATE.

Step 10: Place all spacer rings (97) Step 11: Spacer rings (97) in place. Step 12: Place exhaust valve cover
onto the dual exhaust seat (96). (16) on top of spacer rings (97).

Step 13: Insert exhaust valve cover Step 14: Tighten screws (15) Step 15: Replace free flow knob
screws (15) and tighten by hand. using a Phillips #3 screwdriver (14), knob spring (13) and knob
to 45 in.lbs (5 Nm). nut (12).

Step 16: Tighten knob nut (12) Step 17: Double exhaust installed.
until snug using a 3/8" flat blade
screwdriver.
44 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX L
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 / Gorski 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 main-
tain constant air flow. The helmet should be fitted with a double exhaust when
used for contaminated water diving.

KIT CONTENTS

AQA Part No. Gorski Part No. Item Description Qty per Kit
400112B n/a Plug, Insert, Free Flow 1
400046 1SS-0054 O-ring, Exhaust (Large) 1
17306 n/a Hook Fastener, 2.0 in Blk, Pressure Sensitive 1
17308 n/a Loop Fastener, 1.0 in Blk, Pressure Sensitive 1

Step-by-Step Assembly Instructions

Step 1: Remove nose clearing Step 2: Remove NCD (73). Step 3: Remove oral-nasal mask
device (NCD) knob (71). (32) .

Step 4: Remove microphone (35). Step 5: Remove exhaust valve Step 6: Remove regulator cover
cover screws (15) using a Phil- (17).
lips #3 screwdriver.
45

FREE FLOW KIT PLUG INSTALLATION INSTRUCTIONS (continued)

Step 7: Remove regulator. Step 8: Remove defogger train Step 9: Remove free flow barrel
(28). (29).

Step 10: Lubricate and install o-ring Step 11: Install free flow plug in Step 12: Replace regulator cover
on outside of free flow plug. Place helmet shell (1). Ensure Velcro (17).
Velcro strip on barrel. strip is facing inward.

Step 13: Tighten exhaust valve Step 14: Place Velcro tab on Step 15: Place microphone (35)
cover screws (15) using a Phillips base of microphone (35). on free flow plug.
#3 screwdriver to 45 in.lbs (5 Nm).

Step 16: Reinstall NCD (73). Step 17: Place NCD knob (71) on Step 18: Components removed.
NCD (73) to secure in place.

Step 19: Install Double Exhaust Kit (P/N 400111) on helmet if not already fitted.
46 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX M
CAMERA/LIGHT BRACKET (P/N 400107)
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 / Gorski to
speak directly with a Technical Advisor before proceeding any further.

Step-by-Step Assembly Instructions

Step 1: Remove two retainer port Note: Brackets may Step 2: Line up bracket holes
screws (21) from top corner of be bent to shape as with helmet retainer holes.
helmet using a Phillips #3 screw- required.
driver.

Step 3: Replace the two retainer Step 4: Right hand bracket installed. Step 5: Left hand bracket installed.
port screws (21) and tighten us-
ing a Phillips #3 screwdriver to 45
in.lbs (5 Nm).

Step 6: Left and Right brackets.


47

APPENDIX N – TERMINAL BLOCK COMMUNICATIONS KITS


Terminal Block Hi-Use Communications Module Kit (P/N 400150)
102 Hand tight & 1¼
turn with wrench

23B
101 103

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
23B 1 400122 N/A CAP & PLASTIC FERRULES, BULKHEAD ASSY
101 1 400133 N/A TUBING PLASTIC, PRE-CUT (10PK)
102 1 400152 N/A WIRE TERMINAL BLOCK
103 1 400126 N/A CABLE ASSY, OTS COMS, HI-USE

Terminal Block Marsh Marine Communications Module Kit (P/N 400151)


Hand tight & 1¼
turn with wrench

102

23B
101 104

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
23B 1 400122 N/A CAP & PLASTIC FERRULES, BULKHEAD ASSY
101 1 400133 N/A TUBING PLASTIC, PRE-CUT (10PK)
102 1 400152 N/A WIRE TERMINAL BLOCK
104 1 400125 N/A CABLE ASSY, OTS COMS, MARSH MARINE

WIRE TERMINAL BLOCK (P/N 400152)


102

101

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
101 1 400133 N/A TUBING PLASTIC, PRE-CUT (10PK)
102 1 400152 N/A WIRE TERMINAL BLOCK
48 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX O – TWIST-ON COMMUNICATIONS KITS

Twist-ON Hi-Use Communications Module Kit (P/N 400144)

Hand tight & 1¼


turn with wrench

99
23B
98

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
23B 1 400122 N/A CAP & PLASTIC FERRULES, BULKHEAD ASSY
98 1 400146 N/A CABLE ONLY ASSY, TWIST ON, HI-USE
99 2 400148 N/A TWIST-ON CONN KIT, 2 CONNS ALONE

Twist-on Marsh Marine Communications Module Kit (P/N 400145)

Hand tight & 1¼


turn with wrench

99
23B
100

ITEM QTY AQA P/N GORSKI P/N DESCRIPTION


NO
23B 1 400122 N/A CAP & PLASTIC FERRULES, BULKHEAD ASSY
99 2 400148 N/A TWIST-ON CONN KIT, 2 CONNS ALONE
100 1 400147 N/A CABLE ONLY ASSY, TWIST ON, MARSH MARINE
49

APPENDIX P
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 / Gorski 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 (22) from
the helmet shell (1). Remove the old plastic tubing (101) 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 (102) 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. Insert the connector cable assembly (103 or 104) through the bulkhead cap and ferrules (23b), then
the communication bulkhead (23). Tighten the bulkhead cap and ferrules (23b) hand tight, then 1 1/4
turns further with a 11/16" wrench to secure the cable.

Note: Ensure the two piece ferrules are installed in the following order:
1. Cap.
2. Small ferrule (small side towards helmet)
3. Large ferrule (small side towards helmet).

3. Connector cable assembly is available with Hi-Use (103) (Fig. 3) or Marsh Marine (104) (Fig. 4) connector.

Figure 3 Figure 4
50 Gorski G2000SS Diving Helmet Technical Manual

Wiring Terminal Block for 4-Wire Communications


1. Install connector cable lug rings onto the termi-
nal block (102) per the terminal block pin configura-
tion (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 Figure 5
block with a 3/8" nut driver.

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. Insert the connector cable assembly (98 or 101) into the bulkhead cap and ferrules (23b), then the
communications bulkhead (23).Tighten the bulkhead cap and ferrules (23b) hand tight, then 1 1/4 turns
further with a 11/16" wrench to secure the cable.

Note: Ensure the two piece ferrules are installed in the following order:
1. Cap.
2. Small ferrule (small side towards helmet)
3. Large ferrule (small side towards helmet).

2. Connector cable assembly is available with Hi-Use (98) (Fig. 7) or Marsh Marine (101) (Fig. 8) connector.

Figure 7 Figure 8
51

3. Install connector cable lug rings onto the com-


munication posts (22) 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 communi-
cation 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 (35) to the connector cable as-


sembly (98 or 100) per the wiring diagram (Fig. 11).
Place stripped wires together with the ends of insulation
even. Twist connector (99) (Fig. 10) onto wires pushing
firmly until hand-tight. Wipe sealant in and around con-
ductors 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
52 Gorski G2000SS Diving Helmet Technical Manual

Wiring Terminal Block for 2-Wire Communications


1. Install connector cable lug rings onto the terminal
block (102) 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
Mic
Mic
Speaker
(right)
Speaker
Speaker
(right)
(right)
Speaker
(left)
Speaker
Speaker
Figure 15 (left)
(left)

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

Figure 16 Figure 17
53

APPENDIX Q
Torque Specifications

AQA PN # GORSKI DESCRIPTION / KEY ITEM # TORQUE (IN.LBS) NOTE


PN #
400009 1SS-0015 Screw, Exhaust Valve Cover (15) 45 in.lbs (5 Nm)

400113 1SS-0099 Screw, Latch (4) 140 in.lbs (16 Nm)

400015 1SS-0021 Screw, Retainer Port (21) 45 in.lbs (5 Nm)

400021 1SS-0026 Swagelock Connector (26) 45 in.lbs (5 Nm) Fitted into free flow valve
body (52)
400030 1SS-0038 Manifold Plug (38) 90 in.lbs (10 Nm)

400035 1SS-0043 Screw, Hex, Manifold (43) 80 in.lbs (9 Nm)

400036 1SS-0044 Screw, Hex, Manifold (11) 80 in.lbs (9 Nm) For latch catch assembly

400039 1SS-0047 Port Plug (47) 45 in.lbs (5 Nm)

400082 1SS-0080 Screw, Neck Ring, Lower (80) 20 in.lbs (2 Nm)

400083 1SS-0081 Screw, Buckle Strap (81) 20 in.lbs (2 Nm)

400093 1SS-0091 Screw, Hinge Block Mounting (91) 45 in.lbs (5 Nm)

400094 1SS-0092 Screw, Hinge (92) 45 in.lbs (5 Nm)

400128 N/A Blank Plug (N/A) 90 in.lbs (10 Nm)

AQA PN # GORSKI DESCRIPTION / KEY ITEM # TORQUE (FT.LBS) NOTE


PN #
400017 1SS-0023 Bulkhead Connector (23) 25 ft.lbs (34 Nm)

400054 1SS-0062 Bonnet, Free Flow Valve (62) 35 ft.lbs (47 Nm)

AQA PN # GORSKI DESCRIPTION / KEY ITEM # TORQUE (SEE NOTE) NOTE


PN #
400122 1SS-0108 Cap & Ferrules Bulkhead Assy See Note Cable installed hand tight,
(23B) then 1¼ turn with wrench
400138 N/A Airway Assembly (24) See Note Hand tight, then 1¼ turn
with wrench
400040 1SS-0048 Check Valve (48) See Note Pipe thread, no torque

400041 1SS-0049 Fitting, SCUBA (49) See Note Pipe thread, no torque

400042 1SS-0050 Fitting, Hose (50) See Note Pipe thread, no torque
54 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX R
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
Dow Corning
2200, W Salzburg Road,
Dow Corning 111 All o-rings
Midland Township, MI 48686
(989) 496-1725

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.
55

APPENDIX S
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 or Dow Corning® 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.
56 Gorski G2000SS Diving Helmet Technical Manual

APPENDIX T
ANNUAL SERVICE KIT (P/N 400108)

All Gorski part numbers have been replaced with Aqua Lung (AQA) part numbers.

The individual parts in the Annual Service Kit are labeled with AQA part numbers.

The Key No. (column E) is provided to assist with correct parts identification and refers to the
relevant Exploded Parts Diagram (Appendices A thru I).

A B C D E

New AQA Gorski Item Description Qty per Kit Key No.
Part No Part No
400004 1SS-0007 Nut, Neck Retainer 1 7

400012 1SS-0018 O-ring, Face Port 1 18

400022 1SS-0027 O-ring, Swagelock Conn & Port Plug 2 27

400027 1SS-0034 Valve, Inhalation 1 34

400031 1SS-0039 O-ring, Manifold Plug 2 39

400034 1SS-0042 O-ring, Manifold Connector 2 42

400037 1SS-0045 Gasket, Manifold 1 45

400045 1SS-0053 O-ring, Exhaust (Small) 1 53

400046 1SS-0054 O-ring, Exhaust (Large) 2 54

400050 1SS-0058 Washer, Copper 2 58

400052 1SS-0060 O-ring, Stem, Free Flow Valve 1 60

400060 1SS-0067 O-ring, Regulator Body, Small 2 67

400064 1SS-0069B O-ring, Valve Seat, Regulator 1 See Note

400065 1SS-0069C Plate, Rubber, Valve Piston 1 See Note

400074 1SS-0072 O-ring, Nose Clearing Device (NCD) 2 72

Note: These parts are located inside the LP valve assembly.


57

VII. CHECK LISTS

Checklist 1 G2000SS Diving Helmet Daily Checklist


Checklist 2 G2000SS Diving Helmet Pre-Dive Checklist
Checklist 3 G2000SS Diving Helmet In-Water Checklist for Supervisor
Checklist 4 G2000SS Diving Helmet Post-Dive Checklist
Checklist 5 G2000SS Diving Helmet Monthly Inspection and Maintenance Checklist
Checklist 6 G2000SS Diving Helmet Annual Inspection and Maintenance Checklist
58 Gorski G2000SS Diving Helmet Technical Manual

CHECKLIST 1
G2000SS DIVING HELMET
DAILY CHECKLIST

BEFORE DIVING THE G2000SS 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.

WARNING: Aqua Lung America strongly recommends completion of this checklist


and meeting the minimum requirements provided before using the G2000SS 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 G2000SS diving helmet, a correctly maintained and
serviceable emergency gas system (EGS) must also be used. 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 135 and 150
psig. In addition, the first stage regulator bleed/pressure relief valve should be set
between 180 and 200 psig.

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)
59

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 ASSEMBLY • 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 dam-
age 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 with-
out problems. If necessary lubricate o-rings and
stem (Refer to the technical manual for guidance).
• Ensure the speakers and microphones are
properly installed. (Refer to the technical man-
ual for guidance).
• Ensure that the head liner fits properly and is se-
cured to the inside of the helmet shell. Check for
worn-off Velcro, tears and/or rips. (Refer to the
technical manual for guidance).
60 Gorski G2000SS Diving Helmet Technical 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
NOTE: Ensure that the EGS and the hydrostatic date.
is maintained properly.
• Check the first stage regulator intermediate pres-
sure (IP) setting before each dive.
• Make sure there is no damage to the diver har-
ness and cylinder retainer. Repair or replace if
damaged.

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 to the EGS
cylinder and the hose to the helmet emergency
supply check valve. With the cylinder turned off,
open and close the free flow valve to verify ef-
ficient 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 pressure,
open the helmet free flow valve ¾ to 1 full turn
and confirm a powerful flow of gas coming out of
the defogger train. After confirmation, close the
free flow valve.

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.
61

DAILY CHECKLIST (continued)


ACTION PROCEDURE INITIALS

CHECK THE SECOND • Slowly depress the purge button to check for ex-
STAGE REGULATOR cessive travel. The purge button should travel no
(must be completed by diver/tender) less than 1/16" and no more than 1/8" (1.5 - 3.0
mm) before the regulator begins to flow gas.
• Depress the purge button fully and confirm a
strong flow of gas.

NOTE: If the regulator free flows itself, or


after fully depressing the purge button there
is a weak flow of gas, 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 con-
LEAKS nections (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.
• Ensure the umbilical strain is released.
• 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 Technician: Note comment on the space provided below. Be sure to log maintenance in the
applicable maintenance log.
Comments:
62 Gorski G2000SS Diving Helmet Technical Manual

CHECKLIST 2
G2000SS DIVING HELMET
PRE-DIVE CHECKLIST
BEFORE COMPLETING THIS CHECKLIST, THE DAILY CHECKLIST MUST BE COMPLETED.
BEFORE DIVING THE G2000SS 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.

Note: Aqua Lung America strongly recommends that the diver be assisted by the
tender or supervisor when preparing for diving and conducting the procedures in this
checklist.

WARNING: Aqua Lung America strongly recommends completion of this checklist


and meeting the minimum requirements provided before using the G2000SS 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 G2000SS diving helmet, a correctly maintained and
serviceable emergency gas system (EGS) must also be used. The EGS must be
confirmed as fully functional prior to diving .

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)
63

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 • Ensure the speakers and microphone are func-


CHECK tioning correctly.
(must be completed by diver
and communications operator)

CHECK DRY SUIT • Ensure dry suit inflation valve and exhaust valve
INFLATION HOSE are functioning correctly.
(if applicable, 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, includ-
ing the divers safety harness, umbilical strain
release, EGS hose quick disconnect, boots,
gloves, knife and accessories.
64 Gorski G2000SS Diving Helmet Technical Manual

PRE-DIVE CHECKLIST (continued)


ACTION PROCEDURE INITIALS

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 cylinder valve and take two breaths
from the EGS supply.
• Close the EGS cylinder valve.
• Open main breathing gas supply. Diver reports:
Breathing OK.

NOTE: After checking, the EGS cylinder valve


must be shut leaving the hose pressurized.

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.
• Neck retainer secured with both locking catches
WARNING: Both latch (L and R) engaged on neck retainer.
catches must fit into
• Chin strap properly fastened.
place correctly or the
helmet may flood. • Check adjustment and fit of the diver's safety har-
ness. Umbilical strain release, EGS hose quick
disconnect, boots, gloves, etc.
• Ensure helmet supply pressure is at minimum
130 psig.

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:
65

CHECKLIST 3
G2000SS DIVING HELMET
IN-WATER CHECKLIST FOR SUPERVISOR

WHEN DIVING THE G2000SS DIVING HELMET, THE PROCEDURES IN THIS CHECKLIST
MUST BE COMPLETED.

WARNING: Aqua Lung America strongly recommends completion of this


checklist and meeting the minimum requirements provided before using the
G2000SS 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 IN-
JURY OR EVEN DEATH.

CAUTION: When using the G2000SS diving helmet, a correctly maintained and
serviceable emergency gas system (EGS) must also be used. The EGS must be
confirmed as fully functional prior to diving .

WARNING: When diver uses less than the minimum recommended supply pres-
sure, 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)
66 Gorski G2000SS Diving Helmet Technical Manual

IN-WATER CHECKLIST (continued)

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.

GAS SUPPLY PRESSURE

3. The console operator must maintain a minimum over-bottom pressure gas supply
pressure. Required over-bottom pressures (OBP) for depth are as follows:

Depth OBP
0 - 60 fsw (0 - 18.3 msw) 90 psig (6.2 bar)
61 - 100 fsw (18.6 - 30.5 msw) 115 psig (7.9 bar)
101 - 132 fsw (30.8 - 40.2 msw) 135 psig (9.3 bar)
133 - 165 fsw (40.6 - 50.3 msw) 165 psig (11.4 bar)
166 - 220 fsw (50.5 - 67.1 msw) 200 psig (13.8 bar)

NOTE:
• If the above OBP cannot be supplied, the diver must reduce his
workload to avoid exhaustion.
• The second stage regulator and manifold have a maximum design
pressure of 225 psig (15.5 bar) over-bottom.

Signature: Date:

Comments:
67

CHECKLIST 4
G2000SS DIVING HELMET
POST-DIVE CHECKLIST
THE POST-DIVE CHECKLIST MUST BE COMPLETED AT LEAST ONCE A DAY WHEN DIVING US-
ING THE G2000SS DIVING HELMET.

Note: The procedures in this checklist are to be performed only by personnel who
have received appropriate training.

WARNING: Aqua Lung America strongly recommends completion of this


checklist and meeting the minimum requirements provided before using the
G2000SS 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 IN-
JURY OR EVEN DEATH.

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)
68 Gorski G2000SS Diving Helmet Technical 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 wa-
ter. 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 head liner. Visually inspect for damage and/or deterioration. If the
head liner is wet, air dry it.

NOTE: The liner may be washed as required.

6. 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 hel-
met. Wash with soap and water, rinse with fresh water and allow to dry. DO NOT
allow water to enter the regulator body. Re-install into helmet upon completion.

NOTE: Refer to the technical manual for guidance on installation and removal
of the regulator.

7. Remove the speakers.


69

POST DIVE CHECKLIST (continued)

PROCEDURE INITIALS

8. Remove the microphone from the oral-nasal mask. Wash the oral-nasal mask
with soap and water, rinse with fresh water and allow to dry.

9. Dry the inside of the helmet, including oral-nasal mask, by wiping. If required,
wash with soap and water, rinse with fresh water and allow to dry.

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:
70 Gorski G2000SS Diving Helmet Technical Manual

CHECKLIST 5
G2000SS 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 technical manual for guidance in
conducting each step in the inspection and maintenance of the G2000SS 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.

WARNING: Aqua Lung America strongly recommends completion of this


checklist and meeting the minimum requirements provided before using the
G2000SS 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 IN-
JURY OR EVEN DEATH.

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)
71

MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued)

1. All parts are to be visually inspected for damage or deterioration.


2. Any damaged or defective parts must be replaced.
3. Between annual overhauls certain consumable parts (e.g. o-rings) may be reused if no dam-
age or deterioration is revealed by the inspection process.

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 dete-
rioration. A damaged neck seal must be replaced.
• If the quad ring is dry, lightly lubricate the quad ring.
• Replace the neck dam assembly onto the helmet
and ensure a proper fit.

NOTE: Refer to the technical manual, neck


dam assembly section for guidance.

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

NOTE: Refer to the technical manual, neck


retainer and locking system section for
guidance.

HEAD LINER • Visually inspect for deterioration and/or damage.


If necessary, replace with new head liner.

NOTE: Refer to the technical manual, head


liner section for guidance.
72 Gorski G2000SS Diving Helmet Technical Manual

MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued)

STEPS PROCEDURE INITIALS

COMMUNICATIONS • Without removing the comms system, check condi-


tion of speakers and microphone by visual inspec-
tion. If inspection reveals poor quality of sound, re-
place with new speakers and/or microphone.
• Without removing them, check communication
posts and terminal block (if equipped) for insula-
tor cracks or damage. If necessary, replace with
new posts.

NOTE: Refer to the technical manual, com-


munications section for guidance.

NOSE CLEARING • Check NCD for ease of movement and then re-
DEVICE (NCD) move 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 re-
place. Lubricate o-rings lightly as required.

NOTE: Refer to the technical manual, nose


clearing device section for guidance.

ORAL-NASAL MASK • Remove oral-nasal mask 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 technical manual, oral-


nasal mask section for guidance.

INHALATION VALVE • Remove and visually inspect both components


HOUSING AND for damage and/or deterioration. DO NOT re-
move the inhalation valve from the valve hous-
INHALATION VALVE
(one way valve) ing.

NOTE: All spokes of the "wagon wheel"


must be present.

NOTE: Refer to the technical manual, oral-


nasal mask section for guidance.
73

MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued)

STEPS PROCEDURE INITIALS

SECOND STAGE • Remove the second stage regulator from helmet.


REGULATOR • Visually inspect the flapper valve for damage or
deterioration. If damaged, replace flapper valve.
• Separate the main assembly as follows:
• Unscrew diaphragm housing from main body.
• Unscrew connecting ring.
• Pull out LP valve assembly from main body.
• Visually inspect these assemblies, then wash
them with soap and water, rinse with fresh water
and allow to dry. Compressed air may be used to
assist drying.
• Set the LP valve assembly to the correct position.
Re-adjust as required (refer to technical manual).
• When dry, re-install LP valve assembly into main
body. Lubricate o-ring and install connecting ring.
• Adjust the lever pin (refer to technical manual).
• Insert lever into diaphragm tube, lubricate o-ring
and re-attach diaphragm housing to main body.

NOTE: If regulator performance is suspect, the


LP valve assembly may need to be disassem-
bled and serviced by a trained technician.

NOTE: Refer to the technical manual, sec-


ond stage regulator section for guidance.

FREE FLOW VALVE • Remove the free flow valve knob and check the
KNOB 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 technical manual, free


flow/exhaust valve section for guidance.
74 Gorski G2000SS Diving Helmet Technical Manual

MONTHLY INSPECTION AND MAINTENANCE CHECKLIST (continued)


STEPS PROCEDURE INITIALS

FREE FLOW / EXHAUST • Remove the exhaust valve cover and without re-
VALVE moving the free flow/exhaust valve from the hel-
met, remove the snap ring and flapper valve.
• Visually inspect the flapper valve for damage or
deterioration. Clean the flapper valve with soap
and water, rinse with fresh water and allow to dry.
If damaged, replace the flapper valve.
• Clean the external seating surface on the valve
body (i.e. where the flapper valve makes contact).

NOTE: Refer to the technical manual, free


flow / exhaust valve section for guidance.

MANIFOLD • Without removing the manifold body from the


helmet, remove the manifold plug and clean the
manifold screen. Replace on completion.
• Check both one-way valves for proper operation by
sucking on the umbilical and scuba hose adapters.

NOTE: Refer to the technical manual,


manifold section 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 wa-
ter out of inner airway using compressed air.
FINAL ASSEMBLY AND • Follow the technical manual to assemble helmet
TEST to original condition.
• Pressurize the helmet and perform a functional
test and leak check.

Signature: Date:

Comments:
75

CHECKLIST 6
G2000SS 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 Technical Manual for guidance in
conducting each step in the inspection and maintenance of the G2000SS.

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.

WARNING: Aqua Lung America strongly recommends completion of this check-


list and meeting the minimum requirements provided before using the G2000SS
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 400108.
2. Any damage or defective parts must be replaced.
3. All parts should be cleaned using the standard procedures detailed in the Technical Manual.

TOOLS REQUIRED FOR ANNUAL MAINTENANCE

3/8" Nut Driver 5/16" Flat Blade Screwdriver (Regulator Adjust)


7/16" Nut Driver Phillips #3 Screwdriver
3/16" Allen/Hex Key 15/16" Deep Socket and Driver
1/4" Allen/Hex Key 11/16" Socket and Driver
5/8"Flat OE Low Profile / Slim Wrench 7/8" Deep Socket and Driver
11/16"Flat OE Low Profile / Slim Wrench Torque Screwdriver (20 - 140 inch pounds)
O-Ring Tool (Brass or plastic) Torque Wrench (10 - 40 foot pounds)
3/8" Flat Blade Screwdriver
76 Gorski G2000SS Diving Helmet Technical Manual

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)


DISASSEMBLY - SEQUENCE OF EVENTS
This sequence is for guidance. Maintenance instructions are in the subsequent checklist.

Step Activity Tools Required


1 Remove neck dam assembly.
2 Remove neck retainer (5). 7/16" Nut Driver or Wrench
3/16" Allen/Hex Key
3 If required, remove both (L and R) locking system catches 1/4" Allen/Hex Key
(8A & 8B). 3/16" Allen/Hex Key
Note: No requirement to remove catches unless defective.

4 Remove headlLiner. No Tools Required


5 Remove NCD (73). No Tools Required
6 Remove oral nasal mask (32) (remove microphone first) No Tools Required
7 Remove comms assembly components. 3/8" Nut Driver on Terminals
8 Remove the comms bulkhead assembly (23). 15/16" Deep Socket
9 Release tension from the swagelock connector nut and 5/8" Flat OE Wrench for back up
fitting on airway tube (24). 11/16" Flat OE Wrench on nut
10 Remove free flow knob (14) from the valve. 3/8" Flat Screwdriver
11 Release tension from the valve bonnet (62). 11/16" Socket
12 Unscrew (2) long (11) and (2) short (43) manifold hex screws. 3/16"Allen/Hex Key
13 Remove the manifold body (37) from the helmet shell (1). No Tools Required
14 Remove the manifold Insert (41). No Tools Required
15 Using screwdriver, slightly bend the airway assembly (24) 3/8" Flat Screwdriver
and pull the manifold body end out of the helmet
16 Unscrew swagelock connector (26) and remove the air- 11/16" Flat OE Low Profile
way assembly (24) from the helmet. Wrench
17 Unscrew swagelock connector (26) from the free flow ex- 5/8" Flat OE Low Profile Wrench
haust valve body (52).
18 Unscrew regulator cover (17). Phillips #3 Screwdriver
19 Remove the second stage regulator from the helmet. No Tools Required
20 Remove defogger train (28) from the free flow barrel (29). No Tools Required
Note: Do not use force, it should slide out easily.

21 Remove the free flow valve from the free flow barrel (29). No Tools Required
Note: Do not use force, it should slide out easily.

22 Unscrew the exhaust valve cover (16). Phillips #3 Screwdriver


23 Remove the free flow valve from the helmet. No Tools Required
24 Unscrew the port retainer (20). Phillips #3 Screwdriver
25 Remove the face port (19) and o-ring (18). No Tools Required
77

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)

COMPLETE THE FOLLOWING BOXES PRIOR TO THE CHECKLIST

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

Helmet Serial No: Date:

Technician:
(Print Name)

STEPS PROCEDURE INITIALS

NECK DAM ASSEMBLY


NOTE: Refer to the technical manual, neck dam assembly section 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.
78 Gorski G2000SS Diving Helmet Technical Manual

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)

STEPS PROCEDURE INITIALS


NECK RETAINER AND LOCKING SYSTEM
NOTE: Refer to the technical manual, neck retainer section for guidance.

PULL PINS • Ensure the ease of movement and spring tension


(pre-2011 helmets) of both pull pins. Check for debris inside springs
and for any mechanical damage.
LATCH CATCHES • If required, disassemble both (L and R) latch
(2011 onwards) 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 technical manual, head liner section for guidance.

HEAD LINER • Remove head liner from helmet.


• 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 technical manual, nose clearing device section 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.
79

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)

STEPS PROCEDURE INITIALS

ORAL-NASAL MASK
NOTE: Refer to the technical manual, oral-nasal mask section 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 ser-


vice 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 technical manual, communications section 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 as required.
NOTE: There is no requirement to remove
the posts unless damaged.

COMMUNICATIONS • Visually inspect the internal 4-wire comms terminal


TERMINAL BLOCK block (if fitted) for damage.
(2012 Forward) • Replace as required.
80 Gorski G2000SS Diving Helmet Technical Manual

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)

COMMUNICATIONS • Remove and visually inspect the 4-wire comms


BULKHEAD bulkhead connector and cable (if fitted) for damage.
• Replace the o-ring annually.
NOTE: The ferrules are normally reused.

CONTINUE WITH HELMET DISASSEMBLY AS PER THE SEQUENCE OF


EVENTS OUTLINED ABOVE. WHEN DISASSEMBLY IS COMPLETE, PROCEED
WITH THE MAINTENANCE CHECKLIST FOR EACH ASSEMBLY.

STEPS PROCEDURE INITIALS

SECOND STAGE REGULATOR


NOTE: Refer to the technical manual, second stage regulator section for guidance.

REGULATOR BODY • Remove second stage regulator from the


helmet shell.
• Unscrew the connecting ring and remove the
inner components (LP valve assembly).
• Visually inspect the condition of the main body.
• Clean as required.

DIAPHRAGM • Unscrew the diaphragm housing.


• Visually inspect the diaphragm for cuts and damage.
• If required, wash with soap and water, rinse with
fresh water and allow to dry. If necessary, replace
diaphragm.

NOTE: The diaphragm has a long service


life and is not normally replaced annually.

O-RINGS (3) • Replace the large (1) and medium (2) o-rings on
the main body, diaphragm housing and LP valve.
These are replaced annually.

LOW PRESSURE (LP) • Disassemble and rebuild the LP valve assembly as


VALVE per Excerpt from Poseidon Cyclone 5000 Regulator
Manual. Replace the small o-ring and red disk/seat
inside the LP valve.
81

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)

EXHAUST FLAPPER • Visually inspect for cuts and damage. Wash with
VALVE soap and water, rinse with fresh water and allow to
dry. If necessary, replace exhaust flapper valve.

NOTE: The exhaust flapper valve has


a long service life and is not normally
replaced annually.

REGULATOR METAL • Visually inspect for damage. Clean as required. If


PARTS necessary, replace damaged parts.

STEPS PROCEDURE INITIALS

FREE FLOW / EXHAUST VALVE AND DEFOGGER


NOTE: Refer to the technical manual, free flow / exhaust valve and defogger section for guidance.

FREE FLOW / EXHAUST • Remove the free flow/exhaust valve from the
VALVE BODY helmet shell. Disassemble fully and visually in-
spect all parts for damage. Clean as required.

EXHAUST FLAPPER • Visually inspect for cuts and damage. Wash with
VALVE soap and water, rinse with fresh water and allow to
dry. If necessary, replace exhaust flapper valve.

NOTE: The exhaust 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.

SEAT- FREE FLOW • Visually inspect and check nylon seat condition.
VALVE • If necessary, replace entire seat-free flow valve.

VALVE STEM • Visually inspect for damage, bends and thread


condition.
• If necessary, replace with new valve stem.
82 Gorski G2000SS Diving Helmet Technical Manual

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)

STEPS PROCEDURE INITIALS

FREE FLOW VALVE • Check condition of the guide hole in the knob. It
KNOB 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.

DEFOGGER • Visually inspect the free flow barrel and defogger


train for damage. Replace the o-ring (1) on the
Swagelock connector.

AIRWAY ASSEMBLY • Visually inspect the airway assembly.


• Clean as required. Blow any moisture out of
airway assembly using compressed air.
MANIFOLD
NOTE: Refer to the technical manual, manifold section for guidance.

MANIFOLD BODY • Remove the manifold body, complete, from


the helmet.

CHECK VALVES (2) • Remove check valves and adapters.


• Confirm correct operation of both check valves
by conducting a "suck-and-blow" check on each.
Air should only flow in one direction. If this does
not happen, replace check valve.
O-RINGS (2) • 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.
83

ANNUAL INSPECTION AND MAINTENANCE CHECKLIST (continued)

STEPS PROCEDURE INITIALS


FACE PORT ASSEMBLY
NOTE: Refer to the technical manual, face port assembly section 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.

HELMET REASSEMBLY
• The reassembly sequence of events is the reverse of disassembly.
• Follow the Technical Manual to reassemble the helmet to original condition.
• All components must be clean and fully serviceable prior to assembly.
• All o-rings must be lubricated prior to assembly.
HELMET FINAL TEST
Test the helmet after completion of assembly to confirm that it performs correctly
and that there are no leaks.

Signature: Date:

Technician Comments (e.g. Specific items noted during maintenance):


Comments:
84 Gorski G2000SS Diving Helmet Technical Manual

VIII. SPARE PARTS CROSS-REFERENCE LIST


All Gorski part numbers have been replaced with Aqua Lung (AQA) part numbers
– please use this cross-reference list when ordering spare parts.
NOTE: ALL PARTS SHOULD BE ORDERED USING THE AQA P/N
AQA # Gorski # Description
400000 G2000SSDH Helmet Complete, Gorski
400001 1SS-0001 Shell, Helmet
400003 1SS-0006 Bolt, Neck Retainer (5 Pack)
400004 1SS-0007 Nut, Neck Retainer (5 Pack)
400005 1SS-0009 Spring, Latch (5 pack)
400006 1SS-0012 Nut, Knob (5 Pack)
400007 1SS-0013 Spring, Knob (5 Pack)
400008 1SS-0014 Knob, Free Flow
400009 1SS-0015 Screw, Exhaust Valve Cover (5 Pack)
400010 1SS-0016 Cover, Exhaust Valve
400011 1SS-0017 Cover, Regulator
400012 1SS-0018 O-ring, Face Port
400013 1SS-0019 Port, Face
400014 1SS-0020 Retainer, Port
400015 1SS-0021 Screw, Retainer Port (5 Pack)
400016 1SS-0022 Post, Communication Assembly
400017 1SS-0023 Bulk Head, Communications w/ SS Plug Assembly
400018 1SS-0023A Bulk Head, Communications w/ Installation
400021 1SS-0026 Connector, Swagelock
400022 1SS-0027 O-ring, Swagelock Conn & Port Plug (10 Pack)
400023 1SS-0028 Train, Defogger
400024 1SS-0029 Barrel, Free Flow
400025 1SS-0032 Mask, Oral Nasal
400026 1SS-0033 Housing, Inhalation Valve
400027 1SS-0034 Valve, Inhalation
400028 1SS-0036 Liner, Head
400029 1SS-0037 Body, Manifold
400030 1SS-0038 Plug, manifold (Large)
400031 1SS-0039 O-ring, Manifold Plug (10 Pack)
400032 1SS-0040 Screen
400034 1SS-0042 O-ring, Manifold Connector (10 Pack)
400035 1SS-0043 Screw, Hex, Manifold (5 Pack)
400036 1SS-0044 Screw, Hex, Manifold (5 Pack)
400037 1SS-0045 Gasket, Manifold
400039 1SS-0047 Plug, Port
400040 1SS-0048 Valve, Check
400041 1SS-0049 Fitting, SCUBA
400042 1SS-0050 Fitting, Hose
85

400043 1SS-0051 Cap, Fitting, Brass


400044 1SS-0052 Body, Free Flow Exhaust Valve
400045 1SS-0053 O-ring, Exhaust (Small) (10 Pack)
400046 1SS-0054 O-ring, Exhaust (Large) (10 Pack)
400047 1SS-0055 Valve, Flapper Exhaust
400048 1SS-0056 Ring, Snap Flapper Valve
400049 1SS-0057 Seat, Free Flow Valve
400050 1SS-0058 Washer, Copper (5 pack)
400051 1SS-0059 Stem, Free Flow Valve
400052 1SS-0060 O-ring, Stem Free Flow Valve (10 Pack)
400053 1SS-0061 Washer, Teflon (5 pack)
400054 1SS-0062 Valve, Free Flow Bonnet
400055 1SS-0063 Cover, Diaphragm
400056 1SS-0063A Button, Purge (5 Pack)
400057 1SS-0064 Ring, Snap, Cover (5 Pack)
400058 1SS-0065 Diaphragm, Second Stage
400059 1SS-0066 Housing, Second Stage Diaphragm
400060 1SS-0067 O-ring, Regulator Body (Small) (10 Pack)
400061 1SS-0068 Body, Second Stage Main
400062 1SS-0069 Assembly, Valve
400063 1SS-0069A Seat, Valve
400064 1SS-0069B O-ring, Valve Seat, Regulator (10 Pack)
400065 1SS-0069C Plate, Rubber, Valve Piston (5 Pack)
400066 1SS-0069D Piston, Valve
400067 1SS-0069E Spring (5 Pack)
400068 1SS-0069F Housing, Valve
400069 1SS-0069G Pin, Lever
400070 1SS-0069H Sleeve, Ejector
400071 1SS-0069I Device, Operating
400072 1SS-0070 Ring, Connecting
400073 1SS-0071 Knob, NCD
400074 1SS-0072 O-ring, Nose Clearing Device (NCD) (10 Pack)
400077 1SS-0075 Pad, Nose Neoprene (5 Pack)
400078 1SS-0076 Ring, Quad
400079 1SS-0077 Ring, Neck Upper
400080 1SS-0078 Seal, Neck
400081 1SS-0079 Ring, Neck Bottom
400082 1SS-0080 Screw, Neck Ring Lower (5 Pack)
400083 1SS-0081 Screw, Buckle Strap (5 Pack)
400084 1SS-0082 Bushing, Buckle Strap (5 Pack)
400085 1SS-0083 Buckle, Strap
400086 1SS-0084 Strap, Nylon w/D-Rings
400087 1SS-0085 Body, Welding Shell (Shield)
400088 1SS-0086 Lens, Welding
86 Gorski G2000SS Diving Helmet Technical Manual

400089 1SS-0087 Bracket, Lens Holding (2 Pack)


400090 1SS-0088 Gasket, Welding Lens
400092 1SS-0090 Hinge Block, Welding Lens (2 Pack)
400093 1SS-0091 Screw, Hinge Block Mounting (5 pack)
400094 1SS-0092 Screw, Hinge (5 Pack)
400095 1SS-0093 Spring, Welding Shield
400097 1SS-0095 Bushing, Dual Exhaust
400098 1SS-0096 Seat, Dual Exhaust
400099 1SS-0097 Ring, Spacer (5 Pack)
400102 Shield, Welding Assembly
400103 Neck Ring, Assembly
400104 Set, Communication
400106 Second Stage, Cyclone 5000
400107 Bracket, Light/Camera
400108 Kit, Annual Service, G2000SS
400109 Locking System, Left
400111 Kit, Double Exhaust
400112 Kit, Plug Insert Free Flow
400113 1SS-0099 Screw, Latch 5/16" - 18 x 3/4" Long (5 Pack)
400114 1SS-0100 Retainer, Neck Ring, Mod 1
400120 1SS-0105 Washer, Latch Spring (2 Pack)
400122 1SS-0108 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
400146 Cable Only Assy, Twist-On, Hi-Use
400147 Cable Only Assy, Twist-On, Marsh Marine
400148 Twist-On Conn Kit, 2 conns Alone
87

IX. G2000SS DIVING HELMET ACCESSORIES

Standard Helmet Bag P/N 400804

Helmet Flotation Bag P/N 400805

Bailout Hose Assembly w/ (QD) P/N 400161

• Hose Assy, LP, 33", w/ QD, Yellow P/N 400167


Hose Assy, LP, 6", w/ QD, Yellow P/N 400168

• Hose Assy, LP, 33", 1/4" MNPT, Yellow P/N 400162


Hose Assy, LP, 6", 1/4" MNPT, Yellow P/N 400163

• Fitting, QD, Female, 1/4" FNPT, P/N 400165


Fitting, QD, Male, 1/4" FNPT, P/N 400166
88 Gorski G2000SS Diving Helmet Technical Manual

X. MAINTENANCE NOTES
89

MAINTENANCE NOTES
GORSKI G2000SS DIVING HELMET
GORSKI G2000SS HELMET
TECHNICAL MAINTENANCE MANUAL

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©2012 Aqua Lung International Literature P/N 400143 Rev. 8/12