Aqua Lung GORSKI G2000SS Technical Maintenance Manual

Brand: Aqua Lung

Model: GORSKI G2000SS

Type: Technical Maintenance Manual

www.aqualung.com/militaryandprofessional

GORSKI G2000SS HELMET

TECHNICAL MAINTENANCE MANUAL

GORSKI G2000SS DIVING HELMET

Rev. 8/12

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.

GORKSI G2000SS DIVING HELMET TECHNICAL MANUAL, PN 400143

Gorski G2000SS Diving Helmet PN 400000

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

[email protected]

Trademark Notice

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

Warnings, Cautions and Notes:

Pay special attention to information provided in warnings, cautions, and notes,

that is accompanied by these symbols:

A NOTE is used to emphasize important points, tips, and reminders.

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 WARNING indicates a procedure or situation that if not avoided,

could result in serious injury or death to the user.

2 Gorski G2000SS Diving Helmet Technical Manual

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

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 modied without consent of Aqua Lung America, Inc.•

The product has been misused, damaged, put into a situation or service for which the •

product is not intended or if the product has not been correctly maintained according to

the G2000SS Diving Helmet Technical Manual.

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 ow.•

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

oxygen service.

CAUTION: The helmet should not be used for contaminated water diving (CWD)

when only a single exhaust is tted. A double exhaust adapter kit is available

for CWD. When used for CWD with double exhaust tted, the free ow valve

must be open and properly adjusted at all times throughout the dive, as posi-

tive pressure inside helmet must be maintained.

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).

CONTAMINATED WATER DIVING

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 ow 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 veried 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.

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.

Required over-bottom pressures for depth:

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.

6 Gorski G2000SS Diving Helmet Technical Manual

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 specically so that all new or modied assemblies are

interchangeable with, and may be retrotted 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.

HELMET MAINTENANCE & PARTS LISTS (continued)

GENERAL GUIDELINES

In order to correctly perform the procedures outlined in this manual, it is important to follow 1.

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.

Keep the manual open beside you for reference while performing each procedure. Do not rely 2.

on memory.

All service and repair should be carried out in a work area specically set up and equipped for 3.

the task. Adequate lighting, cleanliness, and easy access to all required tools are essential for

an efcient repair facility.

As each unit is disassembled, reusable components should be segregated and not allowed to 4.

intermix with non-reusable parts. Delicate parts, including inlet ttings and crowns which contain

critical sealing surfaces, must be protected and isolated form other parts to prevent damage

during the cleaning procedure.

Use only genuine Aqua Lung parts provided in the service kits. DO NOT attempt to5. 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 modication of the product and renders all

warranties null and void.

Do not attempt to reuse mandatory replacement parts under any circumstance, regardless of the 6.

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

8 Gorski G2000SS Diving Helmet Technical Manual

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.

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 Prole / Slim Wrench 7/8" Deep Socket and Driver

11/16" Flat OE Low Prole / 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

TOOLS REQUIRED FOR ANNUAL MAINTENANCE

Second Stage Regulator•

Free Flow / Exhaust Valve•

Manifold•

Defogger•

Oral-Nasal Mask•

Nose Clearing Device (NCD)•

Face Port Assembly•

HELMET SUB-ASSEMBLIES IN THIS SECTION

Communications•

Head Liner•

Neck Retainer and Locking System•

Helmet Final Assembly•

Neck Dam Assembly•

Quad Ring Installation•

SECOND STAGE REGULATOR

Step 1: Place diaphragm (65) into

diaphragm housing (66). DO NOT

lubricate the diaphragm.

Step 2: Diaphragm (65) in the

diaphragm housing (66).

Step 3: Install the purge button

(63a) onto the diaphragm cover

(63).

Step 5: Install the diaphragm

cover (63) onto the diaphragm

housing (66).

Step 6: Slightly compress the

diaphragm cover (63) and install

the cover snap ring (64). NOTE:

over-compression will cause

damage to the cover.

Step 8: Install exhaust apper

valve (55) on rear of the dia-

phragm housing (66). DO NOT

lubricate the apper valve.

Step 9: Using snap ring pliers

install the apper valve snap

ring (56).

Step 10: Lubricate and install o-ring

(54) on outside of the diaphragm

housing (66).

Step 4: Purge button (63a) installed

in diaphragm cover (63).

Step 7: Ensure that the cover

snap ring (64) sits securely in the

inside groove.

Step 11: Diaphragm housing

complete.

10 Gorski G2000SS Diving Helmet Technical Manual

Step 12: Lubricate and install small

o-ring (67) on main body (68).

Step 13: O-ring (67) installed on

main body (68).

Step 14: Lubricate and install

small o-ring (67) on LP valve

assembly (69).

SECOND STAGE REGULATOR (continued)

Step 15: O-ring (67) installed on

LP valve assembly (69).

Step 16: Second stage regulator

components ready for assembly.

Step 17: Set the valve, rotate

sleeve so right edge of cut aligns

with center line of lever.

Step 18: Install LP valve assembly

(69) into main body (68).

Step 19: Install connecting ring

(70) and tighten by hand.

Step 20: Connecting ring (70)

securely installed.

Step 21: Use A 5/16" at blade

screwdriver for adjustment.

Step 22: Hold in vertical position. Step 23: Adjust until lever end

is level with main body (68)

top edge.

SECOND STAGE REGULATOR (continued)

Step 24: Insert lever into dia-

phragm tube, tighten by hand.

Step 25: Diaphragm housing

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.

12 Gorski G2000SS Diving Helmet Technical Manual

FREE FLOW / EXHAUST VALVE

Step 1: Breakdown of free ow/

exhaust valve parts.

Step 2: Install small o-ring (53)

onto valve body (52).

Step 3: O-ring (53) installed on

valve body (52).

Step 4: Install o-ring (54) onto the

valve body (52) groove.

Step 5: Put exhaust apper valve

(55) on the valve body (52).

Step 6: Flapper valve (55) in-

stalled on valve body (52).

Step 7: Install snap ring (56) in the

groove on the valve body (52).

Step 8: Snap ring (56) installed. Step 9: Place valve seat (57) into

the valve body (52).

FREE FLOW / EXHAUST VALVE (continued)

Step 10: Thread in the valve seat

(57) with valve stem (59).

Step 11: Place two copper wash-

ers (58) into the valve body (52).

Step 12: Place o-ring (60) into

the bonnet valve (62).

Step 13: Place Teon ring (61)

over the o-ring into the valve

bonnet (62).

Step 14: Place the stem (59)

into the valve body (52) over the

seat (57).

Step 15: Place the valve bonnet

assembly over the stem (59) into

the valve body (52).

Step 16: Thread the valve bonnet

(62) into the valve body (52).

Step 17: Tighten the valve bonnet

(62) with a 11/16" socket to 35 ft.lbs

(47 Nm).

Step 18: Free ow/exhaust valve

assembled.

14 Gorski G2000SS Diving Helmet Technical Manual

MANIFOLD

Step 1: Break down of manifold

assembly.

Step 2: Insert screen (40) into the

manifold body (37). Failure to in-

stall may cause debris to block

the ow of gas to the diver.

Step 3: Line up screen (40) with

the end of threads.

Step 4: Install o-ring (39) onto man-

ifold plug (38). Screw manifold plug

(38) to the manifold body (37).

Step 5: Tighten the manifold plug

(38) with a 7/8" socket to 90 in.lbs

(10 Nm).

Step 6: Install o-ring (27) onto

port plug (47). Using a 3/16" hex

key, screw the port plug (47) to

the manifold body (37).

Step 7: Tighten port plug (47) with

a 3/16" hex key until to 45 in.lbs

(5 Nm).

Step 8: Screw check valve (48)

(with Teon tape) into the rst

port of the manifold body (37).

Step 9: Screw check valve (48)

(with Teon tape) into the 2nd

port of the manifold body (37).

Step 10: Screw scuba tting (49)

(with Teon tape) to the rst check

valve (48) and tighten rmly.

Step 11: Screw hose tting (49)

(with Teon tape) to the 2nd check

valve (48) and tighten rmly.

Step 12: Tighten both check valve

assemblies to the manifold body

(37) with an 7/8" socket. Replace

caps (51).

DEFOGGER

Step 1: Two parts of defogger, low-

er and upper unit.

Step 2: Insert lower unit over the

free ow/exhaust valve body.

Step 3: Push lower unit until it

stops.

Step 4: Line up upper unit with the

lower unit.

Step 5: Slide upper unit over the

bracket of the lower unit.

16 Gorski G2000SS Diving Helmet Technical Manual

ORAL-NASAL MASK

Step 1: Oral-Nasal mask (32) with

inhalation valve (34) and inhala-

tion valve housing (33).

Step 2: Line up and install inhala-

tion valve (34) in the inhalation valve

housing (33). DO NOT lubricate

the valve.

Step 3: Inhalation valve assem-

bly for oral-nasal mask (32).

Step 4: Insert inhalation valve as-

sembly into the pocket on the left

side of the oral-nasal mask (32).

Step 5: Outside view of the

correctly installed inhalation

valve (34) and inhalation valve

housing (33).

Step 6: Insert second stage reg-

ulator into the helmet shell (1).

Step 7: Install regulator cover (17)

and tighten all screws (15) to 45

in.lbs (5 Nm) with a Phillips #3

screwdriver.

Step 8: Install microphone (35) in

the right pocket of the oral-nasal

mask (32).

Step 9: Point microphone wire

downwards..

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 t on the diver’s face and reduces dead space in the

helmet, this helps prevent CO2 build up.

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.

ORAL-NASAL MASK (continued)

Step 10: Install oral-nasal mask (32)

onto the regulator mouthpiece.

Step 11: Install nose clearing de-

vice (73) into the helmet shell (1).

Step 12: Secure NCD knob (71)

on the NCD shaft (73). Ensure

that it is snug.

Step 13: Always check before div-

ing to ensure that no threads are

visible in order to prevent loosing

the knob (71).

Step 14: Inside view of installed

oral-nasal mask assembly.

18 Gorski G2000SS Diving Helmet Technical Manual

NOSE-CLEARING DEVICE (NCD)

Step 1: Breakdown of nose clear-

ing device parts.

Step 2: Install two o-rings (72) into

the grooves using o-ring pick.

Step 3: O-rings (72) installed.

Step 4: Place neoprene pad (75) over

nose cleaning device (73) as shown.

Step 5: Fold over and press the

pad ends together.

FACE PORT ASSEMBLY

Step 1: Place o-ring (18) in the

port groove.

Step 2: O-ring (18) installed in

port groove.

Step 3: Place face port (19) into

the helmet shell (1).

Step 4: Face port (19) installed. Step 5: Place port retainer (20) over

face port (19) and line up holes.

Step 6: Install bottom screw (21)

in the port retainer (20) with a

Phillips #3 screwdriver.

Step 7: Install top screw (21) in

port retainer (20), all holes should

be lined up.

Step 8: Install the remaining

screws (21).

Step 9: Tighten all screws (21) to

45 in.lbs (5 Nm) with a Phillips #3

screwdriver.

20 Gorski G2000SS Diving Helmet Technical Manual

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Aqua Lung GORSKI G2000SS Technical Maintenance Manual

Aqua Lung GORSKI G2000SS Technical Maintenance Manual

Aqua Lung GORSKI G2000SS Technical Maintenance Manual

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