Crewsaver CREWFIT 150N User manual

Date: November 2016
Issue No: 15
Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket
Page
Of 52
1
SERVICE MANUAL
CREWFIT 150N LIFEJACKET
Survitec House, Lederle Lane, Gosport,
Hants. PO13 0FZ, England.
Tel: [phone] Fax: [phone]
email: crewsa[email protected]
Web: www.crewsaver.com

Date: November 2016
Issue No: 15
Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket
Page
Of 52
2
No.
Issue 12
Issue 13
Issue 14
Issue 15
Description
Section outlining the scope of the Manual
added on Index page.
Details of all Automatic Heads, Capsules and
Indicator Clips used.
Information from Bulletin 37 regarding
manifold types now included.
Information from Bulletin 38 regarding
checking the Gas Flange and Inflation Tube
on older jackets now included.
Requirement for Servicing personnel to mark
Service Labels with initials and certificate
number added to Section 8.1.6.
Details of CSL Light added to Section 5
Page 4 - change in procedure for accessing
manuals on the website.
Section 8.1.3.3 - New procedure for fitting
replacement cylinders to Hammar
mechanism.
Section 5.9 and Section 6.5 - Expired L6
Lights to be replaced by CSL Lights.
CSL Light added to Parts List
Reference to Venturi Vacuum System
added (sections 6.1.2, 8.1.2 and Parts List)
Back pressure test added
Date
June 2011
February 2013
March 2014
November 2016
Service Bulletins and Amendments Register

Date: November 2016
Issue No: 15
Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket
Page
Of 52
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Index
Section 1
1.1 Introduction
1.2 Product Description
1.3 Data Sheet
1.4 General Features
1.5 Donning Instructions
Section 2
2.1 Service Station Guidelines
2.2 On Receipt Inspection
2.3 General Care
2.4 Servicing Tools
2.5 Lifejacket Servicing Record Sheet
Section 3
3.1 Unpacking the Lifejacket
Section 4
4.1 Cleaning Lifejackets
Section 5
5.1 Inspection
Section 6
6.1 Testing
Section 7
7.1 Repairs
Section 8
8.1 Assembly
Section 9
9.1 Replacement Parts
Scope
This manual covers primarily the servicing of the Crewfit range of 150N lifejackets. The elements
contained within the manual also cover other types of lifejacket as listed below. Training will have
been given in these lifejackets and if any aspect is critical to its operation this will be shown in this
manual.
1. Corporate Lifejacket
2. Bailiff Lifejacket
3. Pouch Lifejacket
4. Seavest Lifejacket

Date: November 2016
Issue No: 15
Crewsaver - Servicing Manual : Crewsaver Crewfit 150 Lifejacket
Page
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1.1.1. This Service Manual will be published on the Crewsaver website (www.crewsaver.com). Click on PARTNER
/LOGIN at the top of the screen. Personnel who have been trained in the servicing procedures for this
lifejacket will be issued with a Username and Password to enable them to access the download section.
Each manual carries an Issue Number and records of issue are logged by Crewsaver to ensure that the
service network maintains correct and up to date servicing information. Emails will be sent regarding any
new Issues. Periodically service bulletins may be issued which will be published on the Crewsaver website
(www.crewsaver.com). Emails will also be sent. It is the service station's responsibility to regularly check the
website for any new bulletins and to ensure inclusion within the servicing manual. The service bulletin
register at the front of the Manual should be completed.
1.1.2. The information referenced in each section follows a standard servicing procedure by which the inspection
should take place.
1.1.3. This servicing manual details information to enable regular maintenance and servicing of the lifejacket to
help prolong the life of the product and ensure it functions correctly.
1.1.4. The manual should be used as a reference document following training in servicing procedures instructed by
Crewsaver approved personnel. The manual also details the equipment and parts needed for correct
maintenance to be performed.
1.1.5. Servicing must be carried out annually at a service station authorised by the manufacturer .
1.1.6. Regular servicing is to be carried out by qualified personnel trained by Crewsaver and holding a valid
servicing certificate. Certificates are valid for a period of 3 years.
1.1 Introduction
1.2 Product Description
1 yr
1.2.1. The Crewfit 150 is a single chamber 150N inflatable lifejacket.
1.2.2. The lifejacket is CE approved to EN 396 -150N Lifejackets.
1.2.3. The lifejacket is easy to don.
1.2.4. The buoyancy of the jacket is provided by a single chamber with an oral tube to ensure the full buoyancy can
be achieved upon or after inflation.
1.2.5. This lifejacket is inflated either manually or by automatic firing mechanisms.
1.2.6. This lifejacket comes in two different versions, the waist belt version and integral deck safety harness
version which are both available with either a velcro or zipped cover closure.
1.2.7 The outer cover is made from a hard wearing material. The colour of the outer cover is normally red or navy
blue. The cover can sometimes be in other colours, e.g. green or black, to meet special customer
requirements.
1.2.8 The Crewfit Junior is fitted with anti-tamper devices. These are white plastic tubes which cover the cylinder
and capsules.
1
Section

Date: November 2016
Issue No: 15
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1.3.1 Data Sheet
Features:
Chamber Buoyancy:
Buoyancy Category:
Cover Colour
MCA (UK) Approved
SOLAS Approved
CE Approved
Cylinder size
Standard Automatic
Hammar Automatic
Manual Firing head
Manual Override
Oral inflation tubes
Pressure relief valves
Hard wearing cover
Whistle - fitted
Retro-reflective tape
Lifting Becket - fitted
Light - fitted
Spray Hood
Thigh straps - fitted
Fall Arrest Harness
Closure method
Alternative covers
Crewfit 150N Lifejackets
160N
150N
Red, Blue or Black
-
-
X
33g
According
to customer
choice
X
X
N/A
X
X
X
X
Optional
Optional
X
N/A
Velcro or Zip
Fireproof, Heavy Duty
1
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1.3.2 Data Sheet
Features:
Chamber Buoyancy:
Buoyancy Category:
Cover Colour
MCA (UK) Approved
SOLAS Approved
CE Approved
Cylinder size
Standard Automatic
Hammar Automatic
Manual Firing head
Manual Override
Oral inflation tubes
Pressure relief valves
Hard wearing cover
Whistle - fitted
Retro-reflective tape
Lifting Becket - fitted
Light - fitted
Spray Hood - fitted
Thigh straps - fitted
Fall Arrest Harness
Closure method
Alternative covers
Anti tamper devices on cylinders and capsules
Crewfit 150N Junior Lifejackets
100N
150N
Red or Navy
-
-
X
23g
X
-
-
X
X
N/A
X
X
X
X
Optional
-
X
N/A
Velcro
-
X
1
Section

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1
Section
Spanish Gold PU Coated Nylon
Hammar Operating
Mechanism
Firing Head Manual Pull
50mm x 210mm Solas
Approved Retro
Reflective Tape
Oral Tube
Whistle
1.4.1 General Features - Crewfit 150 Non Harness
Red PU Coated Polyester
40mm Sliding Bar
Belt Adjustment Buckle
40mm Black Polyester
Back-strap
Screen print
Crewsaver Badge
SS40 Buckle
Firing Head
pull toggle
40mm Black
Polyester belt

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Issue No: 15
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Spanish Gold PU Coated Nylon
33g CO2
Cylinder
Mk5 Firing Head
and Capsule
Firing Head Manual Pull
50mm x 210mm Solas
Approved Retro
Reflective Tape
Oral Tube
Whistle
1.4.2 General Features - Crewfit 150 Harness
1
Section
Red PU Coated Polyester
50mm Black Nylon
Harness
Screen print
Crewsaver Badge
Square Link
& 3 Bar Link
Firing Head
pull toggle
50mm Black
Nylon belt
D-Ring

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Issue No: 15
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1.4.3 General Features - Crewfit Junior Non Harness
1
Section
Red PU Coated Polyester
25mm Black Polypropylene
Back Strap/ Crutch Strap
Crewsaver Badge
Firing Head
pull toggle
40mm Black
Polyester belt
Spanish Gold PU Coated Nylon
23g CO2
Cylinder
Mk5 Firing Head
and Capsule
Firing Head Manual Pull
50mm x 210mm Solas
Approved Retro
Reflective Tape
Oral Tube
Whistle
SS40 Buckle
40mm Sliding Bar
Belt Adjustment Buckle
Inflation Chamber
Retainer

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Issue No: 15
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1.4.4 General Features - Crewfit Short Non Harness
Spanish Gold PU Coated Nylon
33g CO2
Cylinder
Mk5 Firing Head
and Capsule
Firing Head Manual Pull
50mm x 210mm Solas
Approved Retro
Reflective Tape
Oral Tube
Whistle
1
Section
Red PU Coated Polyester
40mm Black Polyester
Back-strap
Crewsaver Badge
40mm Black
Polyester belt
Firing Head
pull toggle
SS40 Buckle
Screen print

Date: November 2016
Issue No: 15
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CREWFIT
CREWFIT
Don the lifejacket like a normal jacket The backstrap should then be positioned
down the centre of the back.
Th e l ife jac k et wi l l inf l ate
automatically upon immersion
in water. (Pull lanyard down if
manual inflation is required).
Fasten the interlocking
front buckle as shown.
Adjust the belt length by pulling the
webbing through the side buckle to
achieve a secure fit.
(As shown above).
1 2
3
4 5
1
Section
1.5.1 Donning Instructions - Crewfit 150 Non-Harness

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Don the lifejacket like a normal jacket The shoulder straps should then be
positioned down the centre of the back.
Fasten the interlocking front
buckle as shown.
1 2
3
CREWFIT
PERSONS OF
32 KG
OR MORE
CREWFIT
PERSONS OF
32 KG
OR MORE
The lifejacket will inflate
a u t o m a t i c a l l y u p o n
immersion in water. (Pull
lanyards down if manual
inflation is required).
Adjust the belt length by pulling the
webbing through the stainless steel
front buckle to achieve a secure fit
and thread through belt tidy. (As
shown above).
5 6
1.5.2 Donning Instructions - Crewfit 150 Harness
1
Section

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2.1.1 Service stations shall comply with the following as a minimum;
2.1.1.1 Servicing of Inflatable Lifejackets shall be carried out in a fully enclosed area only.
2.1.1.2 The area shall be well lit and protected from direct sunlight.
2.1.1.3 The temperature and humidity shall be sufficiently controlled to ensure that the servicing of inflatable
Lifejackets may be carried out successfully.
2.1.1.4 The area shall be efficiently ventilated but free from draught.
2.1.1.5 Sufficient tools (including specialist tools) shall be available to ensure Lifejackets may be
disassembled, tested and reassembled in accordance with this Manual. These shall include but not
limited to:
2.1.1.5.1 Manometers and pressure gauges.
2.1.1.5.2 Oil free and dry air supply.
2.1.1.5.3 Scales for weighing Gas Cylinders.
2.1.1.5.4 Crewsaver Service tool kit (See 2.6). This is recommended but similar calibrated devices
may also be used.
2.1.1.6 Stock of materials and components to allow efficient servicing with readily available replacement parts
to ensure a prompt service for the customer.
2.1.1.7 Only personnel trained and certified in accordance with Crewsaver requirements are approved to
carry out Servicing and Maintenance. They must be holders of a valid Certificate issued by
Crewsaver.
2.1.1.8 The service station shall be of an approved standard.
2.1.1.9 Procedures shall be introduced to ensure that service bulletins, Manuals and replacement parts are
obtained from Crewsaver.
2.1.1.10 Subsequent to initial approval and thereafter the service station shall be subject to regular surveillance
by Crewsaver.
2.1.1.11 The service station must comply and have met all QA criteria in the Crewsaver servicing protocol file.
2.2.1 On receipt of the Lifejacket(s), check the state of the packaging before opening and notify the owner
and the company delivering the package of any defects or damage.
2.2.2 On opening the package, check the contents for their general condition and quantity.
2.2.3 Prepare Servicing Record Sheet.
2.2.4 Visually inspect the cover and inflation chamber for damage, abrasion, contamination etc. In
accordance with this manual.
2.2.5 Note repairs or replacements required on the record sheet.
2.2.6 Unless obvious damage is evident, test the Lifejacket in accordance with Section 6. If it is considered
that the damage found would cause the Lifejacket to fail the tests then corrective action shall be carried
out prior to testing.
2.2.7 Damaged areas shall only be marked using wax based crayon. Marks shall be with a small circle or
cross. Ballpoint, rollerball or other forms of ink shall not be used. If in doubt refer to Crewsaver for
guidance.
2.2.8 Repairs to the outer cover are limited to that detailed in section 7.1.
2.2.9 Repairs to welded components including the inflation chamber are expressly forbidden.
2.1 Service Stations
2.2 On Receipt Inspection
2
Section

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2.3.1 The Lifejacket should be stowed in accordance with the manufacturer’s instructions.
2.3.1.1 Lifejackets should be stowed in a dry compartment. Avoid high humidity, such as a car boot.
2.3.1.2 Automatic Lifejackets should have stowage facilities which are provided with a method to
encourage moisture removal.
2.3.1.3 Lifejackets should be stowed vertically, for example hung on hooks, in order that any trapped
water or condensation can drain away naturally.
2.3.1.4 Lifejackets should be rinsed in fresh water and dried thoroughly after use.
WARNING
Prior to sponging or washing remove automatic capsules from the firing mechanism. Allow to dry thoroughly
afterwards.
2.3.2 Contaminants such as oil or diesel fuel may be sponged off immediately with clean water and allowed
to dry naturally.
2.3.3 Mud can be removed with a stiff (not wire) brush when dry.
o
2.3.4 The outer cover may be hand washed in good quality mild detergent in cool water (40 C). Rinse well,
drip dry naturally in air.
2.3.5 Sponge the inflation chamber with pure soap solution only. Rinse in clean water immediately, inflate
and allow to dry naturally in air.
WARNING
Do not use proprietary cleaning fluids, thinners, spirits or similar substances.
2.3.6 In cases of severe contamination the unit shall be deemed beyond economic repair and the customer
advised to purchase a replacement lifejacket.
WARNING
Make sure you know how to use and fit this Lifejacket before an emergency occurs.
Always try and inflate the Lifejacket in the water. If already inflated, cross arms over the chest before jumping.
2.3.7 It is advised that personnel are familiarised with the operation of all Lifejackets and lifesaving
appliances.
2.3 General Care
2
Section

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2.4 Lifejacket Servicing Tools
2.5 Lifejacket Service Record Sheet
2.5.1. An electronic copy of the sheet is available to aid reproduction (or copy next page).
2.5.2. Each lifejacket serviced should be recorded either individually or as a batch, showing the serial
numbers and the work performed during the service.
2.5.3. The service record sheet should be signed and a copy given to the owner certifying that the
lifejacket has been serviced.
2.5.4. All replacement parts should be noted - recording either the serial numbers of the component or
the expiry date.
2.5.5 The record sheet shown on the next page is a recommended version. Similar record sheets,
including the same information, may also be used.
2
Section
Fig. 2.4 Table of Tools Required
Crewsaver Servicing Tool Kit
A fine screw driver or tool suitable for removing gaskets
Boning tool
Roller
Brushes
Scissors or good quality trimming shears
“Chinagraph” pencil
Tailors chalk
Fine point indelible pen
1 off metal calibrated metre stick
Scales to weigh gas cylinders 0-1000gram (+1/-1 grams)
Adaptor/tee piece for testing inflation chambers.
Manometer 0-500Mbar
Timing Device
Thermometer 0-40ºC
Crewsaver Vemnturi Vacuum System
Clean and dry air supply
1 off ball pein hammer
450mm wide bag sealer (3mm element)
Back pressure test unit
Suitable large surface area for the work to be carried out
1 off FR steel cabinet (adhesive store)
1 off HD industrial sewing machine (e.g. Singer 96K, Juki, Durkopp etc.)
N.B. In case of difficulty contact Crewsaver direct (Not sewing machines, cabinets or tables - these parts may
be sourced locally.)
Note: Prior consent to carry out any repairs must be pre-approved by Crewsaver. All repairs to stitching must
be in accordance with this manual.
Description Type

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2
Section
LIFEJACKET SERVICING SCHEDULE
SERVICED BY:
CERTIFICATE NUMBER:
VESSEL
W/O Number:
Crewsaver
LAST SERVICED BY DATE OF LAST SERVICE
SERIAL NUMBER/S:
RQ
CHAMBER INSPECTION COMMENTS
GENERAL CONDITION
MATERIAL
WELDS
WEBBINGS
RETRO TAPE
WHISTLE
ORAL TUBES
RELIEF VALVES
MANIFOLDS
Schrader VALVES
CYLINDERS
LIGHT
CYALUME POCKET
BUDDY LINE
RQ
INFLATION MECHANISM COMMENTS
OPERATING MECHANISM
CORD
AUTOMATIC CAPSULE
WASHERS
RETAINING NUT
RETAINING CLIP
TOGGLE
RQ
SPRAY HOOD COMMENTS
FABRIC
ATTACHMENT
VELCRO
REPAIRED ITEMS (COMMENTS)
TYPE
CUSTOMER
RQ
WEBBINGS COMMENTS
WAIST BELT / HARNESS
BACK STRAP
LIFTING BECKET
CROTCH STRAP
BUCKLES
STITCHING
ON
OFF
RELIEF VALVE TEST RESULTS FRONT
CHAMBER
OPEN
CLOSE
REAR
CHAMBER
DATE:
RQ
COVER COMMENTS
MATERIAL
VELCRO
ZIP
PLB POCKETS
PRESSURE TEST RESULTS
FRONT
CHAMBER
REAR
CHAMBER
TIME
TEMP. ON OFF

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2
Section 2
2.6 Lifejacket Servicing Tool Kit
Cylinder Torque Strap
UML Mk5 Auto Socket
Manometer
Valve Extraction Tool
Pressure Measuring
Adaptor
Inflation Adaptor
Turned Socket
Calibrated Socket Driver
(Tighten Cylinder)
Calibrated Socket Driver
(Remove & Replace Locking
Nuts For UML & HR)
Calibrated Torque Driver
(Schraeder Valve)

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3.1 Unpacking
3.1.1 Starting at the inflation mechanism side of the outer cover, un-peel the velcro or pull the zips apart
(zipped version only), exposing the operating head and cylinder. Care should be taken not to snag the
firing line. See Fig 3.1 for Adult version & Fig 3.2 for Junior version.
WARNING: All defects should be noted onto the service record sheet.
3.1.2 Remove the operating mechanisms.
3.1.2.1 Following unpacking refer to:
a.) Manual Operation: Fig 3.3 - Halkey Roberts operating head removal.
b.) Automatic Operation: Fig 3.4 - Crewsaver Mk5 Automatic operating head
removal.
c.) Automatic Operation: Fig 3.6 - United Moulders Mk3 Automatic operating head.
d.) Automatic Operation: Fig 3.7 - United Moulders Mk5 Automatic operating head.
3.1.2.1.1 Automatic Only. Unscrew the Automatic Capsule if fitted from the operating
mechanism. Place to one side for testing and reassembly later. See Section 6
for details.
3.1.2.1.2 Carefully remove the inflation cylinder by unscrewing it from the operating
mechanism. Retain for further Inspection. Refer to Section 5.
3.1.2.1.3 Remove Operating Mechanisms (and upper and lower manifold gaskets on
Halkey Roberts operating heads only) by unscrewing the retaining nut on the
top of the inflation mechanism. Retain for further Inspection. Refer to Section 5.
3.1.2.2 If a Hammar operating mechanism is fitted, remove using the special Hammar operating
head “Service Key". See Fig 3.8. Place to one side for further inspection.
Refer to Section 5.
3.1.3. Remove light and battery if fitted and if required. Place to one side for further inspection. Refer to
section 5.
3.1.4. For Cleaning. Refer to Section 4.
3.1.5. Carry out visual inspection. Refer to section 5.
3
Section

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3
Section
Fig. 3.1.1 Fig. 3.1.2
Fig. 3.1.3 Fig. 3.1.4
Fig 3.1 Unpacking the Crewfit 150 Lifejacket

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Fig 3.2 Unpacking the Crewfit Junior Lifejacket
Fig. 3.2.1 Fig. 3.2.2
Fig. 3.2.3 Fig. 3.2.4
Fig. 3.2.5 Fig. 3.2.6
3
Section